Improved Protective Face Masks

Abstract

The present disclosure relates to improved protective face masks for consumer and professional use, including multiple layers, including a sealing layer, that provide an improved seal, improved comfort, and reduced fogging or poor visibility for eyewear worn in conjunction with the mask.

Description

[Background technology]

[0001] The utility and need for effective masks has been recognized in recent years, both in professional medical settings and for everyday consumer use. While masks are an effective tool in minimizing exposure to potential contaminants and reducing the risk of transmitting certain diseases, masks still pose some practical concerns for their wearers.

[0002] Specifically, a common problem when wearing a mask for those who also wear protective eyewear is the fogging or poor visibility of the eyewear while breathing. This problem has been known and exists for many years. Previous attempts to address this problem have involved thickening the mask fabric and using adhesives to secure the mask to the wearer's skin. None of these approaches have completely solved the problem, and in addition, they sometimes add to the discomfort of wearing the mask.

[0003] To overcome these limitations, the present invention provides a unique approach that utilizes and layers different materials to improve the overall seal created between the inner surface of the mask and the wearer's skin, thereby improving the functionality of the mask and reducing any fogging or poor visibility of eyewear worn in conjunction with the mask. Summary of the Invention

[0004] It is an object of the present invention to provide an improved mask that creates a high level of seal against the wearer's skin, thereby reducing any residual airflow that may result in poor visibility for corrective eyewear or other eyewear, while simultaneously maintaining and improving the mask's ability to protect against the transmission of disease or illness (such as COVID-19).

[0005] Furthermore, use of the layered structure of the present disclosure, according to various embodiments, does not significantly increase the cost of mask production and minimizes the time it takes to load and adjust the mask. [Brief description of the drawings]

[0006] [Figure 1] 1 is a depiction of various mask layers according to some embodiments of the present disclosure. [Diagram 2] 1 is a depiction of an improved mask according to some embodiments of the present disclosure. [Diagram 3] 1 is a depiction of an improved mask in a folded configuration according to some embodiments of the present disclosure. [Figure 4] 1 is a depiction of a methodology for creating an improved mask according to some embodiments of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] In the following description, details are provided to enhance the understanding of various disclosed embodiments, and it will be apparent that the description is not intended to limit the scope of the disclosure to these specific embodiments, and that variations, modifications, substitutions, or equivalents will be apparent to those skilled in the art and should not be considered as significantly departing from the intended scope of the disclosure.

[0008] In some embodiments, a protective face mask according to the present disclosure may have an outer fabric layer and an inner sealing layer. The outer fabric layer may be made of any material conventionally known in the art for the manufacture of protective face masks. The inner sealing layer may be made of a thin, moldable material configured to adhere to the skin of the wearer. For example, the inner sealing layer may be made of an adhesive film or other moldable plastic, such as a thin, treated, or film-like PVC or polyethylene. The advantage of using such a material for the sealing layer is that it provides a stronger seal that more closely conforms to the contours of each wearer's face. Furthermore, although described as "layers," the outer fabric layer and the inner sealing layer may be secured together along their edges such that a substantially continuous surface is formed by the bond, rather than one overlapping the other. In particular, the flexibility of the adhesive film may allow for a seal to occur along all edges of the mask. Furthermore, such adhesive films often react to moisture (such as the wearer's natural sweat) in a manner that further improves the seal between the film and the wearer's skin. In another embodiment, a moisturizer may be pre-applied to the film to help create a seal between the mask and the wearer's skin, as shown in Figure 4. Unlike conventional approaches to improving a seal between the mask and the skin, embodiments of the present disclosure do not require the use of additional adhesives, foams, or thicker mask material to hold the mask on the wearer's face.

[0009] The improved protective face mask according to the present disclosure may be manufactured, packaged, and provided as a separate unit (as shown in Figures 1-3) or may be obtained by modifying an existing face mask as shown in Figure 4. Conventional face masks (surgical, N95, etc.) provide a fabric layer designed to cover the wearer's nose and mouth. Conventional masks often also utilize either wires or other bendable metal materials to deflect the fabric layer to the wearer's face. For such masks, the wires or other bendable members may be bonded to the inner sealing layer to effectively create a mask according to the present disclosure. In some embodiments, any other conventional method for fastening one material layer to another may be utilized to bond the inner sealing layer to the outer fabric layer. This additional inner sealing layer improves the protective qualities of the mask by improving the seal, and also improves the comfort of the wearer by reducing any airflow that would otherwise cause fogging or poor visibility of the wearer's eyewear.

[0010] In another embodiment, an interior fabric layer may also be included. The interior fabric layer may be made of any material conventionally used in the production of face masks (polyethylene, thick pleated cotton, etc.). The interior fabric layer may be made of the same material as the outer fabric layer. As shown in Figures 1-3, the interior fabric layer is disposed on the opposite side of the inner sealing layer from the outer fabric layer. The interior fabric layer is configured to encompass the portion of the inner sealing layer that contacts the outer fabric layer. The inclusion of the interior fabric layer further reduces the risk of airflow between the outer fabric layer and the inner sealing layer, thereby reducing the possibility of fogging or poor visibility of the wearer's eyewear. The interior fabric layer may be secured to the outer fabric layer by any conventional method for securing one fabric to another.

Claims

1. An outer fabric layer having upper and lower edges; an inner sealing layer including a first surface configured to contact the skin of a wearer and a second surface opposite the first surface, the entire second surface being disposed directly on an interior surface of the protective face mask and located on only one side of the outer fabric layer, the inner sealing layer being a moldable plastic configured to form a sealed attachment to the skin of the wearer; Protective face mask.

2. The protective face mask of claim 1, wherein the moldable plastic is made of polyethylene or polyvinyl chloride or is an adhesive film.

3. The protective face mask of claim 2, further comprising an interior fabric layer having an upper edge and a lower edge and disposed between the inner sealing layer and the outer fabric layer.

4. The protective face mask of claim 3, wherein the inner sealing layer is disposed on the interior fabric layer.

5. The protective face mask of claim 4, wherein the inner sealing layer is a strip disposed on the interior fabric layer along its upper edge.

6. A protective face mask as described in any one of claims 3-5, wherein the upper edge of the interior fabric layer is attached to the upper edge of the outer fabric layer and the lower edge of the interior fabric layer is attached to the lower edge of the outer fabric layer.

7. The protective face mask of claim 6, comprising a first seam attaching the upper edge of the interior fabric layer to the upper edge of the outer fabric layer, and a second seam attaching the lower edge of the interior fabric layer to the lower edge of the outer fabric layer.

8. A protective face mask as described in any one of claims 3-7, wherein the interior fabric layer comprises cotton or polyethylene.

9. A protective face mask as described in any one of claims 1-8, wherein the outer fabric layer comprises cotton or polyethylene.

10. A protective face mask described in any one of claims 1-9, wherein the outer fabric layer is rectangular.

11. A protective face mask as described in any one of claims 1-10, comprising a wire or a bendable metal material arranged either along an upper edge of the protective face mask or within an upper edge of the protective face mask.

12. 12. The protective face mask of claim 1, further comprising a pair of straps configured to attach the protective face mask to a wearer.

13. The protective face mask of claim 12, wherein the pair of straps are ear loops.

14. A protective face mask described in any one of claims 1-13, wherein the outer fabric layer includes a plurality of horizontal pleats.

15. A method for producing a protective face mask according to any one of claims 1 to 14, comprising the steps of: bonding the outer fabric layer to the inner sealing layer. Including, How to make a protective face mask.

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