Mask

Abstract

A mask configured to contact a face of a user along a contact surface of the mask, wherein the contact surface is formed by a plurality of components and the mask comprises: 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 having a bespoke profile to conform with a profile of the nasal region of the user; and a main component configured to contact cheek and chin regions 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

[0001] MASK

[0002] Field of the invention

[0003] The present invention relates to a mask configured to seal against a face of a user and a method of manufacturing a mask configured to seal against a face of a user. to the invention

[0004] It is known to provide a mask which is worn to cover at least a portion of the user’s face. Typically, masks contact the user’s face when they are worn. Some embodiments of the invention relate to respirators. It is known to provide masks for providing protection for a respiratory system of the user. These masks work by filtering out particles and / or gases of a certain size or of a certain type. Such masks may be essential in certain settings, for example, within medical institutions and construction sites. A common problem associated with masks is that they are uncomfortable, especially when worn for long periods of time. However, it is also important that a tight seal is formed between the mask and the user’s face so that inward or outward leakage of airflow does not occur, such as the ingress of airborne hazards.

[0005] It is in this context that the present inventions have been devised. of the invention

[0006] In accordance with an aspect of the present invention, there is provided a mask configured to contact a face of a user along a contact surface of the mask. It may be that the contact surface is formed by a plurality of components (of the mask). It may be that the mask comprises a nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask. It may be that the first portion of the contact surface has a bespoke profile to conform with a profile of the nasal region of the user. It may be that the mask comprises a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

[0007] In accordance with another aspect of the present invention, there is provided a method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask. It may be that the contact surface is formed by a plurality of components. It may be that the method comprises determining a bespoke profile for a nose component in dependence on a profile of the nasal region of the user. It may be that the method comprises forming the nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask. It may be that the first portion of the contact surface has the bespoke profile to conform with the profile of the nasal region of the user. It may be that the method comprises providing a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

[0008] It may be that the mask is a respirator.

[0009] Therefore, in accordance with an aspect of the invention, there is provided a respirator configured to contact a face of a user along a contact surface of the respirator. It may be that the contact surface is formed by a plurality of components. It may be that the respirator comprises a nose component configured to contact a nasal region of the user along a first portion of the contact surface of the respirator. It may be that the first portion of the contact surface has a bespoke profile to conform with a profile of the nasal region of the user. It may be that the respirator comprises a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the respirator. In accordance with another aspect of the present invention, there is provided a method of manufacturing a respirator configured to contact a face of a user along a contact surface of the respirator. It may be that the contact surface is formed by a plurality of components. It may be that the method comprises determining a bespoke profile for a nose component in dependence on a profile of the nasal region of the user. It may be that the method comprises forming the nose component configured to contact a nasal region of the user along a first portion of the contact surface of the respirator, the first portion of the contact surface having the bespoke profile to conform with the profile of the nasal region of the user. It may be that the method comprises providing a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the respirator.

[0010] Typically, the nose component and the main component are connected to one another. It may be that the method comprises connecting the nose component and the main component to one another.

[0011] It may be that the nose component and the main component are detachably attached to one another. It may be that the nose component and the main component are permanently attached to one another during assembly. It may be that the nose component and the main component are formed on one another during manufacture.

[0012] Typically, the mask is a face mask, more typically a half face mask which covers the user’s nose and mouth. Typically, the mask is intended to be worn on the user’s face. Typically, the mask is intended to cover the outer respiratory system of the user. That is, the mask is typically intended to cover the nostrils and mouth of the user. Typically, the mask is configured to provide a barrier between the air surrounding the mask and the outer respiratory system of the user. Typically, the mask is arranged to interact with the air inhaled by the user, for example, through particle filtration.

[0013] It may be that the nose component and main component, when connected, form a mask body that is substantially hemispherical or substantially semi-ovoid in shape. Advantageously, the hemispherical or semi-ovoid shape forms a breathing cavity which provides a gap over the tip of the nose and mouth when the mask is worn, so that the same main component can fit people with a wide range of nose shapes. It may be that the contact surface of the mask is a closed curve formed by the contact surface of the nose component and the contact surface of the main component connected to each other at either end.

[0014] Typically, the second portion of the contact surface contacts an area (i.e. the cheek and chin regions) of the user’s chin and cheek. Typically, the main component extends away from the user’s face such that the breathing cavity is formed between the user’s face and the main component. The breathing cavity allows for the passage of air in and out of the user’s nose and mouth. The breathing cavity improves the comfort of the mask because the part of the mask over the mouth of the user does not sit against the user’s face when worn.

[0015] Typically, the contact surface of the mask corresponds to a line of intersection between the mask and the user’s face. Typically, the contact surface is configured to form at least partial seal such that leakage between the environment surrounding the user and the user’s respiratory system, through the contact surface, is prevented. Typically, the main component and the nose component form a mask body. Typically, the mask body is substantially cup shaped. Typically, the mask body has a concave user facing surface. The mask body may have a convex outer surface.

[0016] Typically, a component is intended to refer to a piece of the mask that is manufactured separately and later joined together with other component during assembly of the mask. Typically, the contact surface is provided such that different components of the mask form the contact surface. That is, the contact surface is formed of more than one component.

[0017] Typically, the first portion of the contact surface contacts an area of the user’s nose and / or surrounding the user’s nose (i.e. the nasal region). Typically, the nose component is a customisable component, manufactured to align with the user’s nose profile. Typically, the nose component extends across the nasal bridge of the user. Thus, the contact surface of the mask may extend over the bridge of the nose. It may be that the nose component contacts user’s face on the region of skin covering the nasal bones, upper lateral nasal cartilages and maxilla of the user.

[0018] Typically, the bespoke profile for the nose component is determined using a method of imaging or modelling a three-dimensional surface or object (i.e. a nasal profile of the user). For example, it may be that the bespoke profile is determined by comparing multiple images or videos of the user taken from different angles. In another example, it may be that the bespoke profile is determined using laser triangulation, stereo vision or 3D scanning. In one example, the imaging may comprise inferring a 3D shape (e.g. with low fidelity) by inferring various distances and angles between facial landmarks. In another example, the modelling may comprise approximating a nasal profile by fitting one or more mathematical functions. In another example, modelling may be achieved using artificial intelligence, such as a trained model. It may be that the method comprises performing any one of these imaging or modelling techniques. It may be that the method comprises performing any other imaging or modelling technique known to the skilled person to be suitable for the purpose of determining the bespoke profile corresponding to an individual’s nose. By “profile”, we refer to the three- dimensional shape of a user’s nose.

[0019] Typically, the main component comprises a main component body having a substantially hemispherical shape to cover the user’s nose and mouth whilst also providing the breathing cavity. The main component body typically comprises an aperture for permitting the passage of breathable gas (e.g. air external to the user into the breathing cavity for inhalation by the user. The aperture may also permit connection to other features of the mask.

[0020] It may be that the second portion of the contact surface is contoured so as to match the contours of a reference face shape. The mask may be comprised of a main component selected from a plurality of main components. It may be that the plurality of main components are grouped into a plurality of groups of main components. It may be that the main components in each group are the same as each other. It may be that each main component has a different size and shape to the other main components in a different group, as will be discussed below. It may be that within each group of main components, all main components are the same size and shape. It may be that main components in different groups have a different size and shape to the other main components not in the same group. It may be that within each group of main components, all the main components are contoured so as to match the contours of a reference face shape that is different to the reference face shape of each other group of main components. It may be that the reference face shape corresponds to a reference face shape for a subset of faces of the human population. Typically, the first portion of the contact surface (i.e. the perimeter comprised of the nose component) is shorter than the second portion of the contact surface (i.e. the perimeter comprised of the main component). That is, the majority of the contact surface is formed by the main component. The first portion of the contact surface is part of the nose component, and the second portion of the contact surface is part of the main component.

[0021] Typically, the first portion of the contact surface has a profile determined in dependence on a nasal region profile of the user. Typically, the first portion of the contact surface is configured to conform with the nasal region of the user. Typically, the first portion of the contact surface is contoured, meaning it is shaped so as to fit with another surface and / or component. The first portion of the contact surface typically has the same profile when the mask is worn compared to when the mask is not worn. That is, the first portion of the contact surface may have a permanent profile.

[0022] The first portion of the contact surface is typically adapted to fit the (intended) user’s nasal region. In particular, the nose component may be adapted to match the nasal bridge of the user such that it is bespoke to the user. Typically, the contours of the first portion of the contact surface (i.e. the perimeter of the mask formed by the nose component) matches the contours of the nose bridge of the (intended) user. Typically, the profile of the first portion of the contact surface aligns with the user’s nose when the mask is worn.

[0023] Advantageously, having a contact surface between the mask and the user’s face made up of two components provides for easier and lower cost manufacturing of a mask compared to existing masks, whilst also providing a mask that is comfortable and adapted for the (intended) user. That is, the bespoke profile of the nose component provides comfort when the mask is worn for long periods of time and improves the seal between the mask and the user’s face because it is user specific. The main component, which is not bespoke, is easier and cheaper to manufacture because a generic main component can be used rather than needing to also adapt this component for the specific user. The combination of the two components allows for a balance between providing increased user comfort and protection and reducing manufacturing costs and complexity. In other words, the combination of the two components provides the advantage of reducing the amount of expensive custom manufacture while still being bespoke to provide comfort. Advantageously, when the mask is a respirator, it may be configured to confirm with the BS EN 140:1999 standard. It may be that the respirator is configured such that inward leakage does not exceed 2 %. Typically, a respirator having an inward leakage that does not exceed 2% refers to a respirator which, when worn in a test environment, allows less than 2% of contaminants (e.g. sodium chloride (NaCI) and corn oil aerosols) present in that environment through the face seal and filter. The total amount of contaminants present in an environment may be determined using the dimensions of the test room and the rate of output of the aerosol. Typically, inward leakage refers to the leakage of contaminants through the filter and seal formed by the contact surface when the respirator is tested.

[0024] Advantageously, respirators in accordance with this invention have passed fit testing (which measured leakage from a facial seal) due to the seal formed by the contact surface. Respirators in accordance with this invention have scored at least 100 on PortaCount fit testing, thereby passing the PortaCount fit test.

[0025] Advantageously, respirators in accordance with this invention have scored highly on the Respirator Comfort, Wearing Experience, and Function Instrument (R-COMFI) in comfort with no signs of facial irritation, pinching, itching, redness and sweating present.

[0026] It may be that the main component is selected from a plurality of main components. It may be that each of the plurality of main components has a different size.

[0027] It may be that the method comprises selecting the main component of the mask from a plurality of main components. It may be that each of the plurality of main components has a different size to the other main components within the plurality of main components.

[0028] It may be that the invention extends to a building comprising a nose component of the mask as described herein, and a plurality of main components. It may be that the plurality of main components are grouped into a plurality of groups of main components. It may be that the main components in each group are the same as each other. It may be that each of the plurality of main components in a group has a different size to the other main components within each other group of the plurality of main components. It may be that the main component of the mask described herein is selected from one of the plurality of main components.

[0029] Advantageously, the main component, although not bespoke, can be chosen from a number of predetermined sizes to provide the most suitable fitting main component from a number of different sized main components. Therefore, the nose component can be made with the bespoke profile and the main component can be chosen from a set of main components having different predetermined sizes. As a result, the fit of the mask and customisation to the user can be further improved.

[0030] That is, there may be a plurality of main components which each form the second portion of the contact surface for the respective mask to which it is a part, where the second portion of the contact surface of each of the different sized / shaped main components in the plurality of main components is contoured to a different model face shape.

[0031] It may be that the plurality of groups of main components is a plurality having no more than 1000 different groups of main components. It may be that the plurality of groups of main components is a plurality having no more than 100 different groups of main components. It may be that the plurality of groups of main components is a plurality having no more than 10 different groups of main components. Regardless of the shape and size of the main component, it may be that each main component in the group can fit with the nose component having the bespoke profile.

[0032] The building may be a warehouse, a factory or other manufacturing facility.

[0033] It may be that the bespoke profile is determined by any known method for measuring the profile of a nasal region of the user.

[0034] When the mask is a respirator, it may be that the respirator comprises a filter assembly connectable to the main component by way of a connection component.

[0035] It may be that the method comprises providing a filter assembly and a connection component. It may be that the method comprises connecting the filter assembly to the main component by way of the connection component. Advantageously, the connection component may provide stability and strength for connecting the filter assembly to the main component.

[0036] It may be that the connection component is formed of a semi-rigid material, for example a thermoplastic polymer such as polypropylene. It may be that the connection component is formed of a harder material than the main component, such as acrylonitrile-butadiene-styrene (ABS) or polycarbonate. It may be that the connection component material has chemical, fatigue and heat resistive properties.

[0037] Typically, the connection component is configured to be positioned between the filter assembly and the main component, when the respirator is assembled. The connection component may provide further functionality in addition to allowing the filter assembly to be connected to the main component, as will be discussed below.

[0038] The connection component typically comprises a first connection mechanism for connection to the filter assembly. The connection component typically comprises a second connection mechanism for connection to the main component.

[0039] The connection component may comprise a connection component body having an aperture configured to align with the aperture of the main component to permit the passage of air external to the user through the filter assembly and into the breathing cavity for inhalation by the user. It may be that the aperture of the main component and the aperture of the connection component body are configured to align along an axis extending perpendicular to the planes of the apertures. It may be that the connection component body is substantially circular.

[0040] It may be that the filter assembly comprises a filter cap and a filter holder. A filter is typically placed within the filter holder and the filter cap is sealed attached to the filter holder. The filter may be any filter suitable for filtering air to remove contaminants against particles such as dust, smoke and aerosols. The filter holder typically comprises a connector for connecting the filter assembly to the connection component. The filter cap typically comprises one or more holes for allowing the passage of air into the filter assembly and through the filter. The filter may be any circular filter. For example, it may be that the filter is a circular filter having a diameter of 96.5mm and height of 18mm. It may be that the filter is certified in accordance with BS EN 143:2021. It may be that the filter provides particle filtering efficiency of minimum 99.5% (P3). It will be appreciated that other filters having different dimensions and / or shapes will be envisaged.

[0041] It may be that the aperture of the filter assembly is configured to directly support (e.g. hold) a filter material. That is, the filter material may be supported directly in the connection component rather than between a filter cap and filter holder.

[0042] It may be that the respirator is part of a breathing apparatus such as a powered respirator and / or a full-face respirator. For example, it may be that the respirator is connectable to an air supply or a full-face and / or powered respirator. It may be that the respirator is connected to the powered and / or full-face respirator by way of the connection component.

[0043] It may be that the connection component is provided in a mask other than a respirator. For example, the connection component may be used for connection to a component other than a filter, for example, a breathing tube (in a diving mask), a gas pump (in a CPAP device).

[0044] It may be that the main component and / or the nose component is an injection moulded component. It may be that the method comprises forming the main component and / or the nose component by injection moulding. It may be that the main component and / or the nose component is formed by additive manufacturing, vacuum casting, gravity casting, 3D printing or extrusion. It may be that the method comprises forming the nose component and / or the main component by additive manufacturing, vacuum casting, gravity casting, injection moulding, 3D printing or extrusion.

[0045] It may be that 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.

[0046] That is, the first connection mechanism may be a threaded connection mechanism, a bayonet connection mechanism and / or a push fit connection. The filter assembly may comprise a thread configured to correspond to a thread surrounding the aperture of the main component. The filter assembly may comprise a pin configured to correspond to a slot in the main component, or vice versa. The filter assembly may comprise a groove configured to correspond to a lip in the main component, or vice versa. Advantageously, this allows for easy disassembly of the respirator for cleaning and replacement parts.

[0047] It may be that the connection component is attached to the main component by way of a lip and groove connection.

[0048] That is, the second connection mechanism may be a lip and groove connection mechanism allowing for a push-fit assembly. Advantageously, this allows for easy disassembly of the mask for cleaning and replacement parts whilst also providing stability and rigidity when wearing and using the mask.

[0049] It may be that the main component comprises a resilient inwardly extending flange comprising a face contacting surface. It may be that the face contacting surface at least partly defines a sealing region of the second portion of the contact surface. It may be that the face contacting surface comprises a concave region. It may be that the face contacting surface comprises a convex region.

[0050] It may be that the resilient flange projects inwardly from a perimeter from the main component. It may be that the concave portion is configured to contact the chin region of the user.

[0051] It may be that the face contacting surface is an undulating surface having one or more concave regions and one or more convex regions. It may be that the sealing region is defined when the mask is worn. It may be that the sealing region extends between a first sealing edge and a second sealing edge. It may be that the shortest distance between the first sealing edge and the second sealing edge at any point within the sealing region is dependent on the deformation of the main component when the mask is worn. It will be appreciated that the exact dimensions of the sealing region are dependent on a number of variables including, but not limited to, the face shape and size of the wearer, the tightness of the straps, and the resilience of the material of the main component.

[0052] By concave and convex we refer to the face contacting surface of the flange. The opposite surface of the face contacting surface, which faces away from the user in use, may have the opposite curvature. It may be that the perimeter of the main component defines the outer edge of the flange. It may be that the inner edge of the flange defines the breathing cavity when the mask is worn. It may be that, when the mask is worn, the user’s chin rests in the concave portion.

[0053] Advantageously, the convex and concave regions of the second portion of the contact surface improve the fit, seal and comfort of the mask as they are designed to align with the contours of the user’s face. The convex and concave regions deform to adapt to the user’s face both when the face is relaxed and also to conform and adapt to the face when the user is speaking.

[0054] It may be that the connection component comprises one or more apertures configured to receive one or more straps for attaching the mask to the face of the user.

[0055] It may be that the method comprises providing one or more apertures in the connection component. It may be that the method comprises providing one or more straps through the one or more apertures.

[0056] Advantageously, the connection component provides multiple functionalities which reduces the number of components required for manufacture, thereby reducing both manufacturing complexity and cost. The connection component connects the filter assembly to the main component and functions as a receiver of the straps to thereby form the mask.

[0057] Advantageously, the provision of a number of apertures for the straps allows for the user to adjust the strap positioning as desired to improve comfort when wearing the mask.

[0058] When assembled, the one or more straps may be received through one of the apertures. The one or more straps typically hold the mask to the face when the mask is worn. Therefore, the connection component is pushed towards the user’s face from the force exerted on the connection component by tightening the one or more straps.

[0059] It may be that the nose component and the main component are made of different materials. It may be that the nose component and the main component are formed by different manufacturing processes. The different materials may have different chemical compositions. The different materials may have different physical properties. It may be that the method of manufacturing comprises forming the nose component by a first process and providing the main component formed by a second process, wherein the first and second processes are different from one another.

[0060] Advantageously, providing the nose and main components made of different materials enables the nose and main components to have different properties, which is desirable for improved comfort and fit.

[0061] The material of the nose component may be softer than the material of the main component. The material of the connection component may be harder than the main component and the nose component. The nose component may be thicker than the main component.

[0062] Typically, the main component is formed of a material that is sufficiently flexible such that it is able to conform to the user’s cheek and chin region. The main component may also be able to flex when the mask is worn when the user speaks or otherwise moves their face. Typically, when the mask is worn, the main component deforms due to force exerted on it by the connection component. Typically, the main component is formed of a material that is soft so as to be comfortable when the mask is worn. Advantageously, this allows for improved comfort and sealing when the mask is worn.

[0063] Typically, the nose component is formed of a material that is sufficiently resistant to deformation, such that it does not significantly deform when the mask is worn. That is, there may be some compression of the nose component when the mask is worn but it will not change the bespoke profile of the nose component. Advantageously, this minimises the pressure exerted on the nasal bridge when the mask is worn, whilst the bespoke profile provides a tight seal. Therefore, the performance of the mask, in providing a tight seal for safety and high levels of comfort, is improved.

[0064] It may be that the nose component is made of a material which is non-reactive, nontoxic, resistant to organic and non-organic solvents, and remains strong and flexible over a broad range of high and low temperatures. It may be that the nose component is made of a silicone material having a first grade. Typically, the nose component is formed of a resilient material. It may be that the main component is made of a silicone material having a second grade, different to the first grade of the silicone of the nose component. Typically, the main component is made of a material having one or more properties comprising: high fatigue resistance, high tear resistance, high impact strength, chemical resistance and resistance to temperatures ranging from -30°C to 140°C. It may be that the main component is made of Thermoplastic Elastomer (TPE).

[0065] Typically, the nose component is formed of a material having a modulus of elasticity between 0.000517 to 0.0621 GPa. Typically, the nose component is formed of a material having a compressive modulus between 0.000200 to 0.00590 GPa. Typically, the nose component is formed of a material having a compression set between 2.10% to 200 %. Typically, the nose component is formed of a material having an ultimate tensile strength between 0.138 to 165 MPa.

[0066] Typically, the main component is formed of a material having different properties to that of the material of the nose component. For example, it may be that the main component is made of a material having an ultimate tensile strength between 0.345 to 80.0 MPa (e.g. TPE). Alternatively, the main component may be formed a material having the same properties.

[0067] It may be the maximum thickness of the nose component is greater than the maximum thickness of the main component. It may be that the material of the main component is harder than the material of the nose component. That is, the material of the nose component may be more flexible and / or resilient than the material of the main component.

[0068] It may be that the main component is formed of a material having a Shore A hardness value of at least 40.

[0069] It may be that the main component is formed of a material having 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. It may be that the main component is formed of a material having a Shore A hardness value of at most 80, at most 75, at most 60, at most 65 or at most 50. It may be that the main component is formed of a material having a Shore A hardness value of between 45 and 70 or between 50 and 65.

[0070] It may be that the nose component comprises a first connecting face and the main component comprises a second connecting face. It may be that the nose component and the main component are connected by way of the first and second connecting faces.

[0071] Advantageously, provision of first and second connecting faces provides a larger surface area for connecting the main and nose components compared to an alternative connection, such as connecting edges. This means that the seal between the two components is improved and the connection between the two components is stronger.

[0072] It may be that the first connecting face is formed on a first edge of the nose component and the first portion of the contact surface is formed on a second edge of the nose component. It may be that the nose component comprises a solid body between the first edge and the first portion of the contact surface. The term “solid” here refers to a non-hollow body. Advantageously, this arrangement resists significant deformation of the nose component when the mask is worn (and pressure is exerted on the nose component via the straps, connecting component and main component), which in turn reduces pressure exerted on the nose.

[0073] Typically, the first and second connecting faces have a predefined standard shape. Typically, the first and second connecting faces align with and face one another when the mask is assembled.

[0074] When the main component is selected from a plurality of main components, each of the main components within the group may have a second connecting face to which the first connecting face of the nose component is configured to fit. It may be that the nose component has the first connecting face which fits with (e.g. corresponds to) the second connecting face of all and each of the second connecting faces of the main components of the plurality of main components. Typically, the second connecting face of each main component in the plurality of main components may all have the same shape (and typically also size). That is, the first and second connecting faces may be standardised.

[0075] It may be that the second connecting face comprises a first flat end and a second flat end on either side of a raised central portion of the second connecting face. It may be that the first and second flat ends extend along a first plane. It may be that the first and second ends of the second connecting face are curved within the first plane. It may be that the central raised portion of the second connecting face is higher in a second direction, extending perpendicular to the first plane, than the first and second flat ends are in the second direction.

[0076] It may be that the first connecting face and the second connecting face are adhered to one another.

[0077] It may be that the method comprises providing a first connecting face of the nose component and a second connecting face of the main component. Optionally, it may be that the method comprises adhering the first connecting face and the second connecting face to one another.

[0078] Advantageously, the central raised portion covers the apex of the user’s nose meaning that the tip of the user’s nose is protected.

[0079] Advantageously, the first and second flat ends being curved further increases the surface area available for connecting the two components. This improves the strength of connection between the two components. In addition, the curve improves flexibility of the mask when the user moves their face, whilst still allowing for a tight seal.

[0080] Optionally, the first flat end is configured to rest against the face adjacent to the left or right side of the nose bridge and the second flat end is configured to rest against the face adjacent to the other of the left and right side of the nose bridge. Typically, the first plane may correspond to the horizontal plane when the mask is worn (e.g. with the wearer's head upright or similar). Typically, the second direction may correspond to a vertical plane when the mask is worn. Typically, the second direction may correspond to a perpendicular plane to the first plane when the mask is worn.

[0081] Throughout this document, the vertical and horizontal refer to the vertical and horizontal of the mask when it is orientated as it would be when the mask is worn. In other words, the vertical direction is the direction from the apex of the nose component to the apex of the main component. The horizontal is perpendicular to the vertical and refers to the lateral outermost points of the main component.

[0082] The curve of the first and second flat ends may be concave relative to the interior of the mask. Typically, the first and second flat ends are closer to the contact surface than the central raised portion is to the contact surface. Typically, the first and second flat ends are closer to the user’s face than the central raised portion is to the user’s face, when the mask is worn.

[0083] It may be that the distance in the second direction between the first and second flat ends and the top of the concave portion of the second portion of the contact surface is between 4cm and 8cm.

[0084] It may be that the central raised portion is arched. It may be that the raised central portion comprises a centre between two outer regions on either side of the centre. It may be that the central raised portion extends in the second direction away from the first and second flat ends of the connecting face. It may be that the outer regions have a curved incline in the second direction towards the nose component (i.e. in a positive, upwards direction of the second plane). It may be that the ends of the central raised portion adjacent to the first and second flat ends are lower in the second direction than the centre of the central raised portion is in the second plane.

[0085] It may be that the first and second connecting faces are inclined with respect to the horizontal plane.

[0086] It may be that the second connecting face comprises a first inclined end and a second inclined end on either side of a raised central portion of the second connecting face. Advantageously, this reduces the amount of material required for the nose component, which is more expensive to manufacture because it includes the bespoke profile.

[0087] It may be that the nose and main components are adhered to one another. Advantageously, this method of connection is easy to manufacture.

[0088] It may be that at least one of the main component and the nose component comprises a groove and the other of the main component and the nose component comprises a lip configured to be received in the groove.

[0089] During assembly of the mask, the groove and lip may be fitted together to connect the nose component and the main component to form the mask. Advantageously, this allows for easy disassembly of the mask for cleaning and replacement parts whilst also providing stability, rigidity and a tight seal when wearing and using the mask.

[0090] It may be that the main component has a non-uniform thickness. Optionally, it may be that the maximum thickness of the main component is 4mm. Optionally, it may be that the minimum thickness of the main component is 1mm. Optionally the range of the maximum and minimum thicknesses is 3mm.

[0091] It may be that the thickness of the main component varies. Advantageously, the varying thickness of the main component allows for increased flexibility in the mask, where desired, and increased strength in the mask, where desired. Thus, the main component can be manufactured such that it provides a balance between strength and flexibility.

[0092] It may be that the section of the main component forming the second portion of the contact surface is thinner than the other sections of the main component. For example, the section of the main component forming the second portion of the contact surface is thinner than the front of the main component (i.e. the section furthest away from the user, when the mask is worn).

[0093] It may be that the maximum thickness of the main component is 4mm, 3.5mm, 3mm, 2.5mm, 2mm or 1 ,5mm. It may be that the minimum thickness of the main component is 1 mm, 1.5mm, 2mm, 2.5mm or 3mm.

[0094] It may be that the thickness of the main component is constant throughout the main component. That is, the main component may have a non-varying thickness.

[0095] It may be that the mask comprises a first region of the main component configured to cover the apex of the nose of the user. It may be that the first region of the main component has a greater thickness than a second region of the main component. It may be that the second region corresponds to a region of the main component not in the first region.

[0096] It may be that the method comprises providing a first region of the main component configured to cover the apex of the nose of the user. It may be that the first region of the main component has a greater thickness than a second region of the main component. It may be that the second region corresponds to a region of the main component not in the first region.

[0097] Advantageously, the thicker first region covering the apex of the nose of the user provides structural integrity to prevent the mask (e.g. the main component) from collapsing against the nose.

[0098] It may be that the thicker regions are at least twice as thick as the rest of the main component.

[0099] It may be that the mask comprises a third region of the main component configured to cover the chin of the user. It may be that the third region of the main component has a greater thickness than a fourth region of the main component. It may be that the fourth region corresponds to a region of the main component not in the third region.

[0100] Advantageously, the thicker third region covering the chin of the user provides protection for the chin of the user. In addition, when the user moves their face, the chin typically moves so the provision of the thicker third region over the chin of the user improves the structural integrity of the mask even when the face moves.

[0101] It may be that the thicker region configured to cover the chin of the user is a region of the main component at the opposite end of the mask to the nose component. It may be that the thicker region configured to cover the nose apex of the user is a region of the main component adjacent to the nose component.

[0102] It may be that the mask comprises a first region of the main component configured to cover the apex of the nose of the user and a second region of the main component configured to cover the chin of the user. It may be that the first and second regions of the main component have a greater thickness than a third region of the main component. It may be that the third region corresponds to a region of the main component not in the first or second regions.

[0103] It may be that the method comprises providing a third region of the main component configured to cover the chin of the user. It may be that the third region of the main component has a greater thickness than a fourth region of the main component. It may be that the fourth region corresponds to a region of the main component not in the third region. It may be that the method comprises providing a first region of the main component configured to cover the apex of the nose of the user and a second region of the main component configured to cover the chin of the user. It may be that the first and second regions of the main component have a greater thickness than a third region of the main component. It may be that the third region corresponds to a region of the main component not in the first or second regions.

[0104] It may be that an area of the main component configured to cover the user’s chin region comprises a first layer and a second layer. It may be that the chin region comprises the chin and a front region of the jaw. It may be that the first layer contacts the user’s chin when the mask is worn. It may be that the first layer is a dimple of the face contacting surface. It may be that the second layer defines the breathing cavity.

[0105] It may be that the nose component comprises a nose component body having one or more brace portions extending in away from the contact surface.

[0106] It may be that the method of providing the nose component comprises providing a nose component body having one or more brace portions extending away from the contact surface.

[0107] Advantageously, the one or more brace portions protect the nose, particularly the nose bridge, and also provide structural support for the mask. When the mask is worn, the straps exert a force on the nose component via the connection component and the main component. The brace portions resist compression of the nose component that could be caused by the force originating from the straps.

[0108] It may be that the one or more brace portions are regions of solid material that form bulbous regions surrounding the nasal region of the user. In particular, the one or more brace portions may surround the nasal bridge of the user. Typically, the one or more brace portions extend away from the contact surface between the contact surface and the first connecting face.

[0109] It may be that the main component and the nose component described hereinbefore can be used on a mask other than a respirator. For example, the main component and nose component, having a bespoke profile to conform with a profile of the nasal region of the user, may be provided in a Continuous Positive Airway Pressure (CPAP) machine. Advantageously, the nose component having the bespoke profile to conform with the profile of the nasal region of the user and the main component can be provided in any type of mask where a comfortable, tight seal with the face is required.

[0110] It may be that the bespoke nose component described hereinbefore can be used on a nasal mask independent of the mask component. For example, the nose component having a bespoke profile may be provided in a nasal Continuous Positive Airway Pressure (CPAP) machine.

[0111] This in itself is believed to be novel, therefore in accordance with an aspect of the present invention, there is provided a nasal mask configured to contact a face of a user along a contact surface of the nasal mask. It may be that the contact surface is formed by a nose component configured to contact a nasal region of the user. It may be that the contact surface having a bespoke profile to conform with a profile of the nasal region of the user.

[0112] In accordance with an aspect of the present invention, there is provided a method of manufacturing a nasal mask configured to contact a face of a user along a contact surface of the nasal mask. It may be that the method comprises determining a bespoke profile for a nose component in dependence on a profile of the nasal region of the user. It may be that the method comprises forming the nose component configured to contact a nasal region of the user along the contact surface of the nasal mask. It may be that the contact surface has the bespoke profile to conform with the profile of the nasal region of the user.

[0113] Advantageously, the nose component having the bespoke profile to conform with the profile of the nasal region of the user can be used independently of the main component for nasal masks in which a comfortable, tight seal with the nasal region is required.

[0114] The features described herein of the nose component, which are unrelated to the specific features relating to the main component as such, may be part of the nasal mask.

[0115] It may be that the nose component is selected from a plurality of nose components. It may be that the plurality of nose components are grouped into a plurality of groups of nose components. It may be that the nose components in each group are the same as each other. It may be that each nose component has a different size and shape to the other nose components in a different group. It may be that within each group of nose components, all nose components are the same size and shape. It may be that nose components in different groups have a different size and shape to the other nose components not in the same group. It may be that within each group of nose components, all the nose components have a predetermined generic nasal profile so as to match the nasal profile of a reference face shape that is different to the reference face shape of each other group of nose components. It may be that the reference face shape corresponds to a reference face shape for a subset of faces of the human population.

[0116] That is, there may be a plurality of nose components which each form the first portion of the contact surface for the respective mask to which it is a part, where the first portion of the contact surface of each of the different sized / shaped nose components in the plurality of nose components is contoured to a different model face shape.

[0117] It may be that the plurality of groups of nose components is a plurality having no more than 1000 different groups of nose components. It may be that the plurality of groups of nose components is a plurality having no more than 100 different groups of nose components. It may be that the plurality of groups of nose components is a plurality having no more than 10 different groups of nose components. Regardless of the shape and size of the nose component, it may be that each nose component in the group can fit with the main component.

[0118] It may be that the nasal profile is selected from a plurality of predetermined nasal profiles, where each predetermined nasal profile has a different size and shape to the other nasal profiles.

[0119] That is, the plurality of predetermined nasal profiles may each determine the first portion of the contact surface for the nose component to which it is a part. Typically, each predetermined nasal profile in the plurality of predetermined nasal profiles is contoured to a different model nasal region.

[0120] It may be that the plurality of predetermined nasal profiles is a group of predetermined nasal profiles having no more than 1000 different sized and / or shaped nasal profiles. It may be that the plurality of predetermined nasal profiles is a group having no more than 100 different sized and / or shaped nasal profiles. It may be that the plurality of predetermined nasal profiles is a group having no more than 10 different sized and / or shaped nasal profiles. Regardless of the shape and size of the predetermined nasal profile, it may be that each predetermined nasal profile can be provided on a nose component.

[0121] This in itself is believed to be novel, therefore in accordance with an aspect of the present invention, there is provided mask configured to contact a face of a user along a contact surface of the mask. It may be that the contact surface is formed by a plurality of components. It may be that the mask comprises a nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask. It may be that the first portion of the contact surface has a nasal profile configured to contact the nasal region of the user. It may be that the nasal profile is a predetermined nasal profile selected from a plurality of predetermined nasal profiles. It may be that mask comprises a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

[0122] In accordance with a further aspect of the present invention, there is provided a method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask. It may be that the contact surface is formed by a plurality of components. It may be that the method comprises selecting a predetermined nasal profile from a plurality of predetermined nasal profiles. It may be that the method comprises forming the nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask. It may be that the first portion of the contact surface has the selected predetermined nasal profile. It may be that the method comprises providing a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

[0123] Advantageously, the mask having a nose component having the predetermined nasal profile selected from a plurality of predetermined nasal profile is easier and cheaper to manufacture because the nose component is not bespoke and can therefore be premade. The features described herein of the nose component, which are unrelated to the specific features relating to the bespoke profile as such, may be part of the mask comprising a nose component having the predetermined nasal profile.

[0124] It may be that the main component comprises one or more indents. It may be that the nose component comprises one or more wings. It may be that each wing is configured to fit against a respective indent of the main component. It may be that each wing forms an overlapping region of the first portion of the contact surface in which the first portion of the contact surface overlaps the main component.

[0125] The provision of wings of the nose component fitting against indents in the main component of a mask can be used with masks formed of two components, even if the nose component does not have a bespoke profile.

[0126] It may be that the wings and indents are cooperating wings and indents. That is, each wing and indent that together form the overlapping region cooperate with one another in order to fit against one another.

[0127] Accordingly, there is provided a mask configured to contact a face of a user along a contact surface of the mask. It may be that the contact surface is formed by a plurality of components. It may be that the mask comprises a nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask It may be that the mask comprises a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask. It may be that the main component comprises one or more indents. It may be that the nose component comprises one or more wings. It may be that each wing is configured to fit against a respective indent of the main component. It may be that each wing forms an overlapping region of the first portion of the contact surface in which the first portion of the contact surface overlaps the main component.

[0128] Advantageously, by providing the nose component with wings forming an overlapping region of the first portion of the contact surface, the force caused by the connection between the nose component and the main component is dispersed across a larger surface area compared to the surface area of a joint between the two components, thereby decreasing pressure on the user’s face. This means that the user can wear the mask for long periods of time without experiencing discomfort. The indents provide the further advantage that the overlapping region is provided whilst retaining a contact surface that is flush to the face of the user, which therefore keeps a tight seal of the mask against the face.

[0129] It may be that main component comprises a first indent. It may be that the nose component comprises a first wing configured to fit against the first indent. It may be that the first portion of the contact surface comprises a first overlapping region formed of the first wing. It may be that the first portion of the contact surface comprises a second overlapping region formed of the second wing.

[0130] It may be that the at least one of the first and second indents are formed in the second portion of the contact surface, which is defined by the main component. It may be that the first and second indents form an ‘L shaped’ ledge in the main component.

[0131] It may be that the overlapping region of the first portion of the contact surface is configured to shield the face of the user from contact with a joining edge of the first and second connecting faces.

[0132] Advantageously, the joining edge between the first and second connecting faces is typically where a large amount of pressure is exerted on the face of the user. The overlapping region shields the face of the user from being in contact with the joining edge when the mask is worn. This avoids the pressure from this joining edge being exerted directly onto the face of the user and therefore improves comfort, allowing the mask to be worn for long periods of time without the user experiencing discomfort. Furthermore, since the joining edge does not directly contact the face of the user, the risk of the joining edges pinching the user’s face is reduced.

[0133] It may be that the joining edge between the first and second connecting faces does not form part of the contact surface. Typically, the first and second connecting faces are not defined by the wing of the nose component. Typically, the first and second connecting faces are not defined by the indent of the main component.

[0134] Typically, the wings are arranged between the joining edge and the face of the user when the mask is worn. That is, the joining edge between the first and second connecting faces may be covered by the wings. The wings may form part of the external surface (i.e. the first portion of the contact surface) of the mask, whilst the joining edge is interior to the mask (in that the joining edge is not on an external surface of the mask).

[0135] It may be that the main component comprises one of more support structures configured to oppose a compressive force exerted on the main component when the mask is worn. It may be that the one or more support structures comprise one or more ribs. It may be that the one or more support structures are provided on an external surface of the main component.

[0136] The support structures may be used in a wide range of masks.

[0137] Therefore according to an aspect of the invention, there is provided a mask configured to contact a face of a user along a contact surface of the mask. It may be that the mask comprises a main component configured to contact cheek and chin regions of the user along a portion of the contact surface of the mask. It may be that the main component comprises one of more support structures configured to oppose a compressive force exerted on the main component when the mask is worn. It may be that the one or more support structures comprise one or more ribs. It may be that the one or more support structures are provided on an external surface of the main component.

[0138] Advantageously, the one or more support structures increase the compressive strength of the mask by preventing the main component from buckling under compressive forces which hold the mask held against the face when the mask is worn. This improves the strength and wearability of the mask.

[0139] The one or more supporting structures increase the compressive strength of the main component by providing structures that increase the thickness of the main component in a direction parallel to the compressive force.

[0140] Typically, the compressive force exerted on the main component may be exerted by the straps, or other type of fastener which keeps the mask held against the face when the mask is worn.

[0141] Typically, the one or more support structures extend parallel to the direction of the compressive force exerted on the main component. Typically, the one or more support structures provide compressive strength to oppose the compressive force exerted on the main component. Typically, the one or more support structures extend away from the contact surface.

[0142] The plurality of ribs may be comprised of a group of parallel, narrow protrusions protruding from a surface the main component.

[0143] The external surface of the main component refers to a surface of the main component which is in contact with the external atmosphere when the mask is worn. Advantageously, by providing the one or more support structures on an external surface of the main component, the interior surface of the mask is kept free of ridges, corners and other areas which are difficult to clean. As dust, saliva and other dirt typically collects on ridges and corners, it is beneficial to avoid including such structures on interior surfaces of the mask. By providing the support structures on an external surface of the mask, any dust, dirt or saliva that may collect on these structures is kept external to the mask and the breathing cavity formed therein.

[0144] It may be that the mask comprises straps which are not connected to the mask via the connection component.

[0145] It may be that the connection component comprises an exhalation valve holder configured to attach an exhalation valve to the mask. It may be that the connection component comprises a structural support member configured to provide support to the nose component.

[0146] Advantageously, the connection component is a single component piece which provide multiple functionalities. That is, the connection component allows the installation of an exhalation valve in the mask by providing an exhalation valve holder and also provides structural reinforcement to the nose component. Therefore, the cost and complexity of manufacturing is reduced, and the strength of the mask is increased. When an exhalation valve is to attached to mask, the exhalation valve holder makes the attachment easy to achieve.

[0147] It may be that the exhalation valve holder is configured to facilitate attachment of an exhalation valve to the mask. It may be that the exhalation valve holder is configured to be positioned vertically beneath the chin region of the user when the mask is worn. It may be that the structural support member contacts the nose component. It may be that the structural support member reinforces the nose component.

[0148] It may be the nose component body has a first section and a second section. It may be that the first section comprises the first portion of the contact surface. It may be that the second section extends away from the first section. It may be that the second section comprises a wall having an interior surface, configured to define a breathing cavity when the mask is worn, and an opposing exterior surface. It may be that a thickness of the wall between the interior and exterior surfaces is at most 10mm.

[0149] Advantageously, the nose component is formed of thin walls such that less material is used to form the nose components, whilst retaining structural strength. In addition, the thin wall between provides flexibility in the mask to accommodate facial movement, such as when the user breathes, nods their head, shakes their head or talks.

[0150] Typically, the first section of the nose component contacts the nasal region of the user. Typically, the first section has the bespoke profile of the user’s nasal region. Typically, the first section of the nose component is a rear surface of the mask when the mask is worn. It may be the that second section (e.g. the wall) comprises an uppermost surface (e.g. the exterior surface of the wall) of the mask when the mask is worn. Typically, the second section (e.g. the wall) extends between the first section and a front surface of the mask. It may be that the second section (e.g. the wall) extends in a direction (e.g. substantially) perpendicular to the vertical central axis. It may be that the second section (e.g. the wall) extends away from the user’s face when the mask is worn.

[0151] Typically, the widest part (e.g. lateral width) of the second section is narrower than the widest part (e.g. lateral width) of the first section. The first section may comprise extension pieces which extend beyond the width of the second section so as to form the first and second joining edges with the main component at a distance from the central vertical axis, in a direction perpendicular to the central vertical axis, of at least 3cm, as discussed above.

[0152] The breathing cavity defined by the interior surface of the wall of the second section of the nose component is the same as the breathing cavity described above. It may be that a thickness of the wall between the interior and external surfaces is at most 10mm, for example at most 8mm, such at most 5mm, for example at most 2mm.

[0153] It may be that the mask comprises a lower strap having a first end and a second end. It may be that the first end of the lower strap is attached or attachable to a first lower attachment point of the mask. It may be that the second end of the lower strap is attached or attachable to a second lower attachment point of the mask. It may be that the first and second lower attachment points are positioned in the chin region of the user. It may be that the mask comprises a central strap having a first end and a second end. It may be that the first end of the central strap is attached or attachable to a first central attachment point of the mask. It may be that the second end of the central strap is attached or attachable to a second central attachment point of the mask. It may be that the first and second central attachment points are positioned in the cheek region of the user. It may be that the mask comprises a first upper strap having a first end and a second end. It may be that the first end of the first upper strap is attached or attachable to a first upper attachment point of the mask. It may be that the second end of the first upper strap is attached or attachable to the central strap. It may be that the mask comprises a second upper strap having a first end and a second end. It may be that the first end of the second upper strap is attached or attachable to a second upper attachment point of the mask. It may be that the second end of the upper strap is attached or attachable to the central strap. It may be that the first and second upper attachment points are positioned in the nasal region of the user.

[0154] Typically, at the least one of attachment points is positioned on the connection component. It may be that all of the attachment points are positioned on the connection component.

[0155] It may be that the attachment point apertures are provided on angled projections extending towards the contact surface (i.e. the user’s face, when the mask is worn).

[0156] It may be that the lower, central and first and second upper straps are implemented in a mask not having a nose component and a main component.

[0157] Therefore, in accordance with an aspect of the invention, there is provided a mask configured to contact a face of a user along a contact surface of the mask. It may be that the mask comprises a mask body. It may be that the contact surface is formed by a mask body configured to contact nasal, cheek and chin regions of the user. It may be that the mask comprises a lower strap having a first end and a second end. It may be that the first end of the lower strap is attached or attachable to a first lower attachment point of the mask body. It may be that the second end of the lower strap is attached or attachable to a second lower attachment point of the mask body. It may be that the first and second lower attachment points are positioned in the chin region of the user. It may be that the mask comprises a central strap having a first end and a second end. It may be that the first end of the central strap is attached or attachable to a first central attachment point of the mask body. It may be that the second end of the central strap is attached or attachable to a second central attachment point of the mask body. It may be that the first and second central attachment points are positioned in the cheek region of the user. It may be that the mask comprises a first upper strap having a first end and a second end. It may be that the first end of the first upper strap is attached or attachable to a first upper attachment point of the mask body. It may be that the second end of the first upper strap is attached or attachable to the central strap. It may be that the mask comprises a second upper strap having a first end and a second end. It may be that the second upper strap is attached or attachable to a second upper attachment point of the mask body. It may be that the second end of the upper strap is or attachable attached to the central strap. It may be that the first and second upper attachment points are positioned in the nasal region of the user.

[0158] Advantageously, the provision of straps at three different regions vertically spread along the face means that the mask is securely fitted to the user’s face. Advantageously, the first and second upper straps are arranged to attach, at one end, to the central strap. This means that the upper strap, which attached to the mask in a nasal region of the user, is angled downwards away from the eye area. This improves comfort of the mask as it would be inconvenient and uncomfortable if the straps were to extend towards the user’s eye area, where the skin is particularly sensitive.

[0159] Typically, the mask body is a portion of the mask configured to cover the outer respiratory system of the user.

[0160] Typically, at least one of the first upper strap, the second upper strap, the central strap and the lower strap are formed of elastic material. Typically, at least one of the first upper strap, the second upper strap, the central strap and the lower strap comprise a buckled strap. Typically, at least one of the first upper strap, the second upper strap, the central strap and the lower strap comprise adjustment mechanisms configured to tighten and loosen the straps as desired by the user.

[0161] It may be that, when the mask is worn, the first and second upper straps are angled downwards, towards the user’s ears. It may be that, when the mask is worn (i.e. when the user’s head is upright such that the nose is vertically above the mouth), the central strap is angled upwards, towards the user’s ears.

[0162] It may be that the first and second upper attachment points are orientated to retain a strap at angle of at most 45°, for example at most 35°, such as at most 25°, typically at most 15° below the horizontal direction. It may be that the first and second central attachment points are orientated to retain a strap at angle of at most 70°, for example at most 50°, such as at most 40°, typically at most 30° above the horizontal direction. It may be that the first and second lower attachment points are orientated to retain a strap at angle of at most 60°, for example at most 40°, such as at most 30°, typically at most 20° above the horizontal direction.

[0163] It may be that least one of the second ends of the first and second upper straps are attached to the central strap by way of a detachable fastener. It may be that the fastener comprises at least one of: a buckle, hoop / thread, button, clasp and hook / loop. It may be that at least one of the second ends of the first and second upper straps are permanently attached to the central strap. It may be that at least one of the second ends of the first and second upper straps are permanently attached to the central strap by way of adhesive or rivets. Other types of permanent connections will be envisaged.

[0164] It may be that each of the one or more apertures are provided on a projection of the connection component. It may be that at least one of the projections is configured to attach to the connection component at an attachment point. It may be that the attachment point is selected from more than one possible attachment point per strap.

[0165] It may be that the method comprises providing the one or more apertures on a projection of the connection component. It may be that the method comprises attaching at least one of the projections to the connection component at an attachment point selected from more than one possible attachment point per strap. According to a further aspect of the invention there is provided a mask configured to contact a face of a user along a contact surface of the mask. The mask may comprise a mask body. It may be that the contact surface is formed by a mask body configured to contact nasal, cheek and chin regions of the user. It may be that the mask comprises one or more straps for attaching the mask to the face of the user. It may be that the one or more straps are each attached or attachable to the mask body. It may be that at least one of the one or more straps are configured to attach to the mask body at an attachment point. It may be that the attachment point is selected from more than on possible attachment point per strap.

[0166] According to another aspect of the invention there is provided a method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask. It may be that the method comprises providing a mask body. It may be that the contact surface is formed by the mask body configured to contact nasal, cheek and chin regions of the user. It may be that the method comprises providing one or more straps for attaching the mask to the face of the user, each strap attached or attachable to the mask body. It may be that the method comprises attaching at least one of the one or more straps to an attachment point selected from more than one possible attachment point per strap.

[0167] Advantageously, by providing a plurality of attachment points per strap, the positions of the strap can be changed so that the user can alter the fit of the mask for optimal comfort. In particular, the attachment point of the strap determines where across the face the strap will fall, so it is beneficial that the attachment point can be adjusted to avoid certain areas of the skin, such as the eye region or sore patches of skin.

[0168] It may be that the mask comprises one or more straps for attaching the mask to the face of the user. It may be that at least one of the one or more straps is attached to the mask at an attachment point. It may be that the attachment point is selected from more than one possible attachment point per strap.

[0169] It may be that the plurality of attachment points comprises a number of discrete attachment points. That is, when assembling the mask, the user can decide which of a plurality of attachment points for each strap of the mask should be used. It may be that there are at least 2 discrete attachment points per strap. It may be that there are at least 3 discrete attachment points per strap. It may be that there are at least 4 discrete attachment points per strap.

[0170] It may be that there is same number of attachment points for each strap. It may be that that is a different number of attachment points different straps.

[0171] It may be that the connection between the projection and the mask body (e,g, connection component) is achieved by dovetail connections on the projection and on the mask body (e.g. the connection component). It may be that other connection types could be used, including any form of snap / push fit connection.

[0172] It may be that the plurality of attachment points comprises a continuous range of attachment points. That is, when assembling the mask, the user can decide which attachment point across a range of continuous positions for the attachment point for each strap of the mask should be used.

[0173] It may be that the continuous range of attachments points is provided by a track. It may be that at least one of the more straps is moveable along a track.

[0174] Optional features disclosed above are optional features of each aspect of the invention.

[0175] An example embodiment of the present invention will now be illustrated with reference to the following Figures in which:

[0176] Figure 1 shows a perspective exploded view of a respirator according to an aspect of the invention;

[0177] Figure 2 shows a cross section of an exploded view of a respirator according to an aspect of the invention;

[0178] Figure 3 shows a perspective assembled view of a respirator according to an aspect of the invention;

[0179] Figure 4 shows a cross section of an assembled view of a respirator according to an aspect of the invention; Figure 5 shows a component of a respirator according to an aspect of the invention;

[0180] Figure 6 shows a cross section of a component of a respirator according to an aspect of the invention;

[0181] Figure 7 shows a component of a respirator according to an aspect of the invention;

[0182] Figure 8 shows a cross section of a component of a respirator according to an aspect of the invention;

[0183] Figures 9 and 10 shows a component of a respirator according to an aspect of the invention on a user;

[0184] Figure 11 shows a component of a respirator according to an aspect of the invention;

[0185] Figure 12 shows a cross section of a component of a respirator according to an aspect of the invention;

[0186] Figure 13 shows a component of a respirator according to an aspect of the invention;

[0187] Figure 14 shows a component of a respirator according to an aspect of the invention;

[0188] Figure 15 shows a cross section of a component of a respirator according to an aspect of the invention;

[0189] Figure 16 shows a flowchart of a method according to an aspect of the invention;

[0190] Figure 17 shows a perspective view of a component of a respirator according to an aspect of the invention;

[0191] Figure 18 shows a cross section of an assembled view of a respirator according to an aspect of the invention;

[0192] Figure 19 shows a perspective exploded view of a respirator according to an aspect of the invention;

[0193] Figure 20 shows a perspective assembled view of a respirator according to an aspect of the invention;

[0194] Figure 21 shows a perspective view of a main component and a nose component of a respirator according to an aspect of the invention;

[0195] Figure 22 shows a side view of a main component and a nose component of a respirator according to an aspect of the invention;

[0196] Figure 23 shows a perspective top view of a nose component according to an aspect of the invention; Figure 24 shows a cross section of a nose component along line A-A’ according to an aspect of the invention;

[0197] Figure 25 shows a side view of a main component according to an aspect of the invention;

[0198] Figures 26 and 27 show a component of a respirator according to an aspect of the invention;

[0199] Figure 28 shows a side view of a respirator according to an aspect of the invention and

[0200] Figure 29 shows a front view of an alternative component of a respirator according to an aspect of the invention;

[0201] Figure 30 shows a side view of the component shown in Figure 29; and

[0202] Figure 31 shows an example of assembling the component shown in Figure 31.

[0203] Detailed Description of an Example Embodiment

[0204] Figure 1 shows a perspective exploded view of a respirator according to an aspect of the invention. Figure 2 shows a cross section of an exploded view of a respirator according to an aspect of the invention. The respirator 100 includes a main component 200, to cover the nostrils and mouth of a user 400, and a nose component 300 which extends across the bridge of the user’s nose. The respirator 100 also includes a connection component 500 that connects to the nose and also to a filter assembly 600. The filter assembly 600 comprises a filter cap 610 and a filter holder 620.

[0205] Figure 3 shows a perspective assembled view of the respirator 100 according to an aspect of the invention. Figure 4 shows a cross section of an assembled view of the respirator 100 according to an aspect of the invention. In the assembled respirator 100, the nose component 300 and the main component 200 are joined together, for example by adhering the two components together, e.g. using an adhesive. Although not shown from the angle of Figure 3, the connection component 500 is connected to the main component 200 and the filter assembly 600 is connected to the connection component. Figure 3 shows the straps 560a, 560b which attach to the connection component 500 to hold the respirator 100 to the user 400. The respirator 100 contacts the user’s face 400 along a contact surface 150, represented by a dashed line. The contact surface is made up of a first portion 151 , which is part of the nose component 300, and a second portion 152, which is part of the main component 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.

[0206] Figure 5 shows a perspective view of the main component 200 of the respirator 100 according to an aspect of the invention. Figure 6 shows a cross section of the main component of the respirator 100 according to an aspect of the invention. The main component is formed of a main component body 210. The main component body 210 has varying thickness including an apex region 220a, which covers the user’s nose apex when worn. The main component body 210 has a space 230 formed by lip 250 for attaching to the connection component 500. The top of the main component 200 is formed as a main component connecting face 240, functioning as the second connecting face discussed above. The main component connecting face 240 has horizontal flat ends 241 on the outer ends of the main component connecting face 240. The horizontal flat ends 241 sit on the region of skin covering the nasal bones, upper lateral nasal cartilages and maxilla of the user, on either side of the nose of the user, when the respirator 100 is worn. The centre of the main component connecting face 240 is a curved face 242 having an arch shape, functioning as the raised central portion of the second connecting face. The curved face 242 sits above the nose of the user, when the respirator 100 is worn. The main component 200 is made of flexible material to allow for the respirator to conform to the user’s face when worn, providing both comfort and sealing.

[0207] Figure 7 shows the nose component 300 of the respirator 100 according to an aspect of the invention. Figure 8 shows a cross section of the nose component 300 of the respirator 100 according to an aspect of the invention. Figures 9 and 10 show the nose component 300 of the respirator 100 according to an aspect of the invention on the user 400. The nose component 300 has a nose component body 310. The bottom of the nose component body 310 is formed as a nose component connecting face 340, functioning as the first connecting face discussed above. The nose component connecting face 340 has horizontal flat ends 341 on the outer ends of the nose component connecting face 340. The horizontal flat ends 341 sit on the region of skin covering the nasal bones, upper lateral nasal cartilages and maxilla of the user, on either side of the nose of the user, when the respirator 100 is worn. The centre of the nose component connecting face 340 is a curved face 342 having an arched shape. The curved face 342 sits above the nose of the user, when the respirator 100 is worn. The nose component 300 comprises a nose component body 310. The nose component body 310 has rounded regions 320a, 320b on either side of a nose protection region 330. The rounded regions 320a, 320b and the nose protection region 330 function as the one or more brace portions discussed above. The rounded regions 320a, 320b and nose protection region 330 are thicker than the nose component connecting face 340 and the first portion 151 of the contact surface 150. The nose protection region 330 protects the nose from any potential impact and adds structural integrity the respirator 100 when worn. The nose protection region 330 sits above the nose of the user, when the respirator 100 is worn. The rounded regions 320a, 320b provide further structural integrity to the respirator 100 when worn. The rounded regions 320a, 320b sit on the region of skin covering the nasal bones, upper lateral nasal cartilages and maxilla of the user, on either side of the nose of the user, when the respirator 100 is worn. When the user wears the respirator 100, the rounded regions 320a, 320b and the nose protection region 330 provide mechanical strength to keep the curved face 342 and the first portion of the contact surface 151 spaced apart from one another by resisting compressive forces from the tension in the straps 560a, 560b via the connection component 500 and the main component 200.

[0208] Figure 11 shows the connection component 500 of the respirator 100 according to an aspect of the invention. Figure 12 shows a cross section of the connection component 500 of a respirator 100 according to an aspect of the invention. Figure 13 shows the connection component 500 of the respirator 100 according to an aspect of the invention. The connection component 500 comprises a connection component body 510 having a space 530 to align with the space 230 of the main component 200, when assembled. The space 230 of the main component 200 has a larger diameter than the space 530 of the connection component 500. The connection component 500 also has a number of apertures 540a, 540b, 540c, 540d through which the straps 560a, 560b can be attached, as shown in Figure 13. The connection component 500 is attached to the main component 200 using the groove 550. In particular, the groove 550 receives the lip 250 of the main component 200, thereby functioning as the second connection mechanism of the connection component discussed above. The respirator 100 can be assembled by pushing the lip 250 into the groove 550 due to flexibility of the material of the main component.

[0209] The connection component 500 has a screw thread 520 to which the filter assembly 600 can be screwed to, thereby functioning as the first connection mechanism of the connection component discussed above. The screw thread 520 is positioned around the perimeter of the space 530 and extends from the front surface of the connection component 500, that is the outermost surface of the connection component 500 when the respirator 500 is worn, towards the rear surface of the connection component 500, that is the surface opposite to the front surface.

[0210] Figure 14 shows the filter assembly 600 of the respirator 100 according to an aspect of the invention. Figure 15 shows a cross section of the filter assembly 600 of the respirator 100 according to an aspect of the invention. As previously discussed, the filter assembly 600 comprises the filter cap 610 and the filter holder 620. The filter cap comprises a number of vents 615a, 615b, 615c which permit passage of air between the exterior and interior of the respirator 100. A filter 625 is placed in between the filter cap 610 and the filter holder 620 and the filter cap 610 and the filter holder 620 are joined together. When the user breathes in, air is in drawn in through the air vents 615a, 615b, 615c. The air then passes through the filter 625, along the filter holder 620 towards the user 400 through the air passage 640 into breathing cavity 700. The filter holder 620 and filter cap 610 are connected using a snap-fit / push-fit / pressure-fit connection. This is achieved with a hook on the filter cap 610 and a groove on the filter holder 620 (annular snap joint) or purely through friction. However, other methods of connection will be envisaged.

[0211] Figure 16 shows a flowchart of a method 1600 according to an aspect of the invention. The method 1600 is a method for manufacturing a respirator having both a nose component and a main component. The method 1600 comprises the first step of determining 1610 a bespoke profile for the nose component. This includes performing at least one imaging technique which enables the 3D shape of a user’s nose to be modelled. The bespoke profile is customised to the (intended) user of the respirator and may be determined by laser scanning the user’s face. Other methods could include Light Detection and Ranging (LIDAR), (stereo)photogrammetry and inference from 2- D images (using machine learning or similar). Once the bespoke profile is determined, the nose component is formed 1620 with the bespoke profile which forms a first portion of a contact surface intended to contact the user’s face when the respirator is worn.

[0212] The next step in method 1600 comprises providing 1630 a main component, which may be achieved by injection moulding, however other methods of production will be envisaged. The provision of the main component includes selecting 1635 the main component from a plurality of main components of a group of a finite size. Each of the main components has a different size and is suitable for different face shapes / sizes. When providing the main component, it may be that this includes selecting the suitably sized main component from the plurality of main components that is most appropriate for the (intended) user’s face shape / size. Providing 1630 the main component may include providing one of more support structures, such as those described in relation to Figure 25 below.

[0213] When the respirator is assembled, the nose component and the main component form a contact surface which contacts the user’s face. The part of the nose component forming the contact surface, that is the first portion of the contact surface, is formed with a bespoke profile corresponding to the profile of the nasal region of the user.

[0214] The method 1600 comprises connecting 1640 the nose component and the main component to one another, which may be achieved by adhering the components (e.g. using an adhesive) or a push-fit, lip and groove connection, however other methods of connection will be envisaged. In alternative embodiments, the nose component may be formed directly on the main component. The method step 1640 may include connecting the main component and the nose component by joining the first portion of the contact surface and the second portion of the contact surface along a first joining edge and a second joining edge on either side of a central vertical axis of the contact surface.

[0215] As part of manufacturing the respirator, the method 1600 comprises providing 1650 a filter assembly and connection component. The filter assembly houses a P3 certified Draeger filter (Draeger is a trade mark of Draegerwerk AG & Co, KgaA, Lubeck, Germany). The filter assembly is connected 1670 to the main component by way of the connection component, where the filter assembly is screwed to a screw thread on the connection component. However other methods of connection will be envisaged. The connection component, with the filter assembly attached, is connected to the main component by a push-fit, lip and groove connection. However other methods of connection will be envisaged. When the respirator is assembled, the connection component is pushed into the main component and the filter assembly is screwed onto the connection component.

[0216] The connection component is provided 1660 with one or more apertures and one or more straps threaded through the one or more apertures. The one or more apertures are located around the edge of the connection component. The connection component provides multifunctionality of connecting the straps to the respirator, connecting the filter assembly to the respirator and providing structural stability.

[0217] As part of forming 1620 the nose component, a first connecting face is formed. As part of providing 1630 the main component, a second connecting face is provided. The first and second connecting faces are surfaces which are used to connect the nose and main component to one another when the respirator is assembled. In this particular example, the respirator is assembled by adhering the first and second connecting faces to one another.

[0218] As part of forming the nose component, the nose component is provided with one or more brace portions which extend away from the first portion of the contact surface. The brace portions are provided as solid bulbous regions protecting the nasal bridge, which provide structural support.

[0219] As part of providing the main component, the main component is provided with regions having a greater thickness than other regions of the respirator, including a first region to cover the user’s nose apex. This thicker region provides both protection and structural support, where desired, particularly at vulnerable points of the respirator (e.g. tip of nose) which protrude from the face.

[0220] It will be appreciated that the order of method steps of the method 1600 are provided as an example, but other orders are possible. In addition, it will be appreciated that not all method steps shown in the method 1600 are required.

[0221] Figure 17 shows a perspective view of a main component 800 according to an aspect of the present invention. Figure 18 shows a cross section of an assembled view of a respirator 100 comprising the main component 800 according to an aspect of the present invention. The main component 800 comprises a resilient flange denoted generally by single-headed arrow 805. The flange 805 extends between the outer edge 815 and the 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 an undulating surface, functioning as the face contacting surface, which is denoted by double sided arrow 835. When the respirator is worn, not all of the face contacting surface 835 contacts the user’s face. Instead, a portion of the face contacting surface 835 contacts the user’s face to form a seal along a sealing region denoted generally by arrow 845. The sealing region 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 external atmosphere. The first sealing edge 855 is the line of intersection between the user’s face, the respirator and the breathing cavity. The dotted line 885 represents the apex of the face contacting surface 835 so when the respirator is placed on the face, the apex 885 is the first part of the main component to contact the face. The main component 800 comprises a convex region 890 which curves away from the user and a dimple 895, functioning as the concave region, which curves towards the user. As shown in the cross section, the user’s chin rests in the dimple 895 when the respirator is worn.

[0222] Figure 19 shows a perspective exploded view of a respirator 1000 according to an aspect of the invention. Figure 20 shows a perspective assembled view of a respirator 1000 according to an aspect of the invention. The respirator 1000 includes a main component 2000, to cover the nostrils and mouth of a user 400, and a nose component 1900 which extends across the bridge of the user’s nose. The respirator 1000 also includes a connection component 2400 that connects to the nose and also to the filter assembly 600. The filter assembly 600 comprises a filter cap 610 and a filter holder 620 as discussed above in relation to Figure 1.

[0223] In the assembled respirator 1000, the nose component 1900 and the main component 2000 are joined together, for example by adhering the two components together, e.g. using an adhesive. Other methods of connection between the main component 2000 and the nose component 1900 will be envisaged. The connection component 2400 is connected to the main component 2000 and the filter assembly 600 is connected to the connection component 2400. Figure 20 shows the straps 2060a, 2060b, 2060c which attach to the connection component 2400 to hold the respirator 2000 to the user 400. The respirator 1000 contacts the user’s face 400 along a contact surface 1950, represented by a dashed line. The contact surface is made up of a first portion 1951 , which is part of the nose component 1900, and a second portion 1952, which is part of the main component 2000. The nose component 1900, main component 2000 and the connection component 2400 will now be described below.

[0224] Figures 21 and 22 show a perspective view and a side view, respectively, of a main component 2000 and a nose component 1900 of a respirator according to an aspect of the invention.

[0225] The nose component 1900 defines the first portion 1951 of the contact surface and the main component 2100 defines the second portion 1952 of the contact surface. The first portion 1951 of the contact surface is made up of wings 1981 , 1982 which each fit into an indent 1983, 1984 in the main component 2000. An example of this is shown in the side view of Figure 22, where the wing 1981 fits into an indent 1983 in the main component 2000. The indent 1983 forms an L shaped ledge against which the wing 1981 sits.

[0226] The first portion 1951 of the contact surface is therefore made up of two overlapping regions 1985, 1986 in which the contact surface is formed by the nose component 1900 but the wings 1981 , 1982 overlap the main component 2000.

[0227] Figure 22 also shows the joining edge 1990 between the nose component 1900 and the main component 2000. The joining edge 1990 forms a corner which exerts pressure on the face of the user when the user wears the mask. However, the wing 1981 sits between the user’s face and the joining edge 1990 to protect the user’s face from direct contact with the joining edge.

[0228] Figure 23 shows a perspective top view of a nose component 1900 according to an aspect of the invention. Figure 24 shows a cross section of a perspective bottom view of the nose component 1900 along line A-A’. The nose component 1900 comprises a nose component body 1910 which is formed of a first section and a second section. The first section is the rear section of the respirator 1000 and includes the first portion 1951 of the contact surface. These figures provide a further view of the nose component 1900 which shows the wings 1981 , 1982.

[0229] The second section of the nose component 1900 has a wall 1945 which has an exterior surface 1960 which is in contact with the external atmosphere when the respirator 1000 is worn. On the opposite side to the exterior surface 1960, the nose component 1900 has an interior surface 1955 which defines the breathing cavity with the main component 2000 when the respirator 1000 is assembled and worn. The thickness, T, of the wall 1945 is 2mm in this example, though it will be appreciated that the thickness could be more or less than 2mm.

[0230] The nose component 1900 has a connecting face 1940 which is inclined with respect to the horizontal and, when the respirator 1000 is assembled, connects to the main component 2000 as shown in Figure 22.

[0231] Figure 25 shows a side view of the main component 2000. The main component 2000 comprises three ribs on an external surface of the main component 2000. Two of the ribs 2031 , 2033 are shown, whilst a third rib (shown in Figure 19) is covered by the strap 2060b. The strap 2060b is shown in a position that corresponds to how the strap 2060b would be placed when the respirator is worn. As shown by arrow F, the strap pulls the main component 2000 towards the user’s face in the direction F. The ribs 2031 , 2033 are parallel to the strap 2060b and oppose the compressive force F in the direction F’, which is directly opposite to the direction of the compressive force F. Although not shown in Figure 25, it will be appreciated that the other side of the main component 2000 also includes ribs.

[0232] The main component 2000 has a connecting face 2040 which is inclined with respect to the horizontal and, when the respirator 1000 is assembled, connects to the connecting face 1940 of the nose component 1900 as shown in Figure 22.

[0233] Figures 26 and 27 illustrate a connection component 2400 of a respirator 1000 according to an aspect of the invention. Figure 26 shows a front view of the connection component 2400 and Figure 27 shows a side view of the connection component 2400. The connection component 2400 comprises a connection component body 2410 having a space 2430 to align with the space of the main component 2000, when assembled.

[0234] The connection component 2400 also has a number of apertures 2440a, 2440b, 2440c, 2440d, 2440e, 2440f through which straps can be attached. The apertures are provided on angled projections 2445a, 2445b, 2445bc, 2445d, 2445e, 2445f. The connection component 2400 has a screw thread 2420 to which the filter assembly 600 can be screwed to, thereby functioning as the first connection mechanism of the connection component discussed above. The screw thread 2420 is positioned around the perimeter of the space 2430 and extends from the front surface of the connection component 2400, that is the outermost surface of the connection component 2400 when the respirator 1000 is worn, towards the rear surface of the connection component 2400, that is the surface opposite to the front surface.

[0235] The connection component 2400 has an exhalation valve holder 2460 which enables an exhalation valve (not shown) to be attached to the respirator to which the connection component 2400 is a part.

[0236] The connection component body 2410 is made up five portions. A central portion 2410c is the portion of the body in which the screw thread 2420 is provided. An upper portion 2410a of the connection component body 2410 is joined to the central portion 2410c of the connection component body 2410 by way of an upper join portion 2410b. The upper portion 2410a of the connection component body 2410 functions as the structural support member discussed hereinbefore and is angled inwards (i.e. towards the user’s face when worn) to support and reinforce the nose component. A lower portion 241 Oe of the connection component body 2410 is joined to the central portion 2410c of the connection component body 2410 by way of a lower join portion 241 Od. The exhalation valve holder 2460 is provided in the lower portion 241 Oe of the connection component body 2410 and is angled inwards (i.e. towards the user’s face when worn) to rest under the chin of the user. The connection component body 2410 comprises a channel 2450 which can be used to facilitate assembly of the respirator 1000.

[0237] Figure 28 shows a side view of the respirator 1000 worn on the user’s face 400 according to an aspect of the invention. The respirator 1000 includes the nose component 1900, the main component 2000 and the connection component 2400. Figure 28 shows two ribs 2031 , 2033, where a third rib 2032 is covered by the strap 2060b.

[0238] As shown in Figure 28, a first end of the lower strap 2060a is attached to the connection component 2400 by aperture 2440f on angled projection 2445f, which functions as the lower attachment point described above. Similarly, a first end of the central strap 2060b is attached to the connection component 2400 by aperture 2440d on angled projection 2445d, which functions as the central attachment point described above. Finally, a first end of the first upper strap 2060c is attached to the connection component 2400 by aperture 2440b on angled projection 2445b, which functions as the first upper attachment point described above. It will be appreciated that this strap arrangement is mirrored on the other side of the respirator, where the first upper strap 2060c is replaced by a second upper strap (not shown). The lower and central straps 2060a, 2060b extend around the user’s head to the other side of the connection component 2400. The first upper strap 2060c is attached to the central strap 2060b by way of a fastener 2065. The user’s eye region is therefore avoided as the first upper strap 2060c extends downwards away from the eye region. The lower strap 2060a, central strap 2060b and first upper strap 2060c each have a slide 2070a, 2070b, 2070c which enable the user to adjust the length of the straps 2060a, 2060b, 2060c to suit them as desired.

[0239] Figure 29 shows a front view of an alternative component of the respirator 1000 according to an aspect of the invention. Figure 30 shows a side view of the component shown in Figure 29. Figure 31 shows an example of assembling the component shown in Figure 31. The component shown in Figures 29 to 31 is an alternative connection component 2500 to connection component 2400 shown in Figures 26 and 27.

[0240] The connection component 2500 shown in Figures 29 to 31 is similar to the connection component 2400 shown in Figures 26 and 27, but with the hereinafter described differences. Like reference numerals are used in Figures 29 to 31 to illustrate features of the connection component 2500 which are equivalent to the features of the connection component 2400 shown in Figures 26 and 27, but with the first two numerals changed from 24 to 25. For example, the connection component body 2410 becomes the connection component body 2510.

[0241] The connection component 2500 differs from the connection component 2400 in that the angled projections 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f are removable from the connection component body 2510. That is, the angled projections 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f are clips. In addition, along the outer perimeter of the connection component 2500 there are a number of connection holes 2575a, 2575b, 2575c, 2575d, 2575e, 2575f which can be used to connect to the angled projections 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f to form the attachment point for each of the straps 2060a, 2060b, 2060c. The angled projections 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f include a plug to fit into the socket formed by the connection holes 2575a, 2575b, 2575c, 2575d, 2575e, 2575f. There are a number of connection holes for each strap so that the user can adjust the straps to achieve the most comfortable fit for their face and head shape. The thick black arrows show the distribution of the connection holes for each strap.

[0242] The first plurality of holes 2575a can be used to attach the angled projection 2545a for the second upper strap to the connection component 2500. The second plurality of holes 2575b can be used to attach the angled projection 2545b for the second upper strap 2060c to the connection component 2500. The third plurality of holes 2575c can be used to attach the angled projection 2545c for the first end of the central strap 2060b to the connection component 2500. The fourth plurality of holes 2575d can be used to attach the angled projection 2545d for the second end of the central strap 2060b to the connection component 2500. The fifth plurality of holes 2575e can be used to attach the angled projection 2545e for the first end of the lower strap 2060c to the connection component 2500. The sixth plurality of holes 2575f can be used to attach the angled projection 2545f for the second end of the lower strap 2060c to the connection component 2500. In this example, the connection between the angled projections 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f and the connection holes 2575a, 2575b, 2575c, 2575d, 2575e, 2575f is a dovetail connection. However, other types of connection between the angled projections and the connection holeswill be envisaged.

[0243] In summary, the contact surface between the respirator and the user’s face is made up of two components, where the nose component is adapted to conform with the user’s face to provide a first portion of the contact surface around the nose and the main component is standardised and provides a second portion of the contact surface. This provides the advantage of reducing the cost of manufacturing the respirator because the bespoke part, which is more expensive, makes up a smaller portion of the contact surface and also provides improved comfort and sealing because it has a customised fit.

[0244] In addition, the main component forms a breathing cavity over the tip of the nose, which again further improves 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 which means that the respirator can accommodate noses of different sizes and shapes within the same sized main component. Moreover, the nose component has a solid structure which resists deformation to provide increased support to the respirator when pressure is exerted on the face by the respirator being held to the head. Furthermore, the main component has varying thickness to strengthen particular areas of the respirator that require additional strengthening and is flexible to provide comfort even when the user wearing the respirator moves their face, e.g. to speak.

Claims

Claims1. A mask configured to contact a face of a user along a contact surface of the mask, wherein the contact surface is formed by a plurality of components and the mask comprises: 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 having a bespoke profile to conform with a profile of the nasal region of the user; and a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

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

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

5. The mask according to claim 4, wherein each of the one or more apertures are provided on a projection of the connection component, wherein at least one of the projections is configured to attach to the connection component at an attachment point, and wherein the attachment point is selected from more than one possible attachment point per strap.

6. The mask according to 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 mask, and the second end of the lower strap is attached or attachable to a second lower attachment point of the 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 mask, and the second end of the central strap is attached or attachable to a second central attachment point of the 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 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 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 mask according to any preceding claim, wherein the nose component and the main component are made of different materials and / or wherein the nose component and the main component are formed by different manufacturing processes; optionally wherein the main component is formed of a material having a Shore A hardness value of at least 40.

8. The mask according to any preceding claim, wherein the nose component comprises a first connecting face and the main component comprises a second connecting face, and the nose component and the main component are connected by way of the first and second connecting faces.

9. The mask according to any preceding claim, wherein the main component comprises one or more indents and the nose component comprises one or more wings, each wing configured to fit against a respective indent of the main component, and wherein each wing forms an overlapping region of thefirst portion of the contact surface in which the first portion of the contact surface overlaps the main component.

10. The mask according to claim 9 when dependent on claim 8, wherein the overlapping region of the first portion of the contact surface is configured to shield the face of the user from contact with a joining edge of the first and second connecting faces.

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

12. The mask according to any preceding claim, comprising a first region of the main component configured to cover the apex 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 not in the first region.

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

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

15. The mask according to any preceding claim, wherein the nose component comprises a nose component body:having one or more brace portions extending away from the contact surface; or having a first section and a second section, the first section comprising the first portion of the contact surface and the second section extending away from the first section, wherein the second section comprises a wall having an interior surface configured to define a breathing cavity when the mask is worn and an opposing exterior surface, wherein a thickness of the wall between the interior and exterior surfaces is at most 10mm.

16. The mask according to any preceding claim, wherein the main component comprises one of more support structures configured to oppose a compressive force exerted on the main component when the 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 provided on an external surface of the main component.

17. The mask according to any preceding claim, wherein the mask is a respirator.

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

19. A method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask, wherein the contact surface is formed by a plurality of components and the method comprises: determining a bespoke profile for a nose component in dependence on a profile of the nasal region of the user; forming the 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 having the bespoke profile to conform with the profile of the nasal region of the user; andproviding a main component configured to contact cheek and chin regions of the user along a second portion of the contact surface of the mask.

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

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

22. The method of claim 21 comprises providing the one or more apertures on a projection of the connection component and attaching at least one of the projections to the connection component at an attachment point selected from more than one possible attachment point per strap.

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

24. The method of manufacturing a mask according to any of claims 19 to 23, comprising fitting a first wing of the nose component against a first indent of the main component and fitting a second wing of the nose component against a second indent of the main component such that the first portion of the contact surface comprises a first overlapping region formed of the first wing and a second overlapping region formed of the second wing.

25. The method of manufacturing a mask according to any of claims 19 to 24, comprising providing a first region of the main component configured to cover the apex 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 not in the first region.

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

27. The method of manufacturing a mask according to of claims 19 to 26, comprising providing one of more support structures configured to oppose a compressive force exerted on the main component when the 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 external surface of the main component.

28. The method of manufacturing a mask of any of claims 19 to 27, comprising selecting the main component of the mask from a plurality of main components, each of the plurality of main components having a different size to the other main components within the plurality of main components.

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

30. A mask configured to contact a face of a user along a contact surface of the mask, the mask comprising a main component configured to contact cheek and chin regions of the user along a portion of the contact surface of the mask, wherein the main component comprises one of more support structures configured to oppose a compressive force exerted on the main component when the mask is worn.

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

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

33. A mask configured to contact a face of a user along a contact surface of the mask, the mask comprising: a mask body, wherein the contact surface is formed by a mask body configured to contact nasal, cheek and chin regions 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 are configured to attach to the mask body at an attachment point, and wherein the attachment point is selected from more than one possible attachment point per strap.

34. A method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask, comprising: providing a mask body, wherein the contact surface is formed by the mask body configured to contact nasal, cheek and chin regions of the user; providing one or more straps for attaching the mask to the face of the user, each strap 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 per strap.

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