Neck gaiter

Abstract

A neck gaiter for use as personal protective equipment comprises a hollow fabric tube 2 with a nose piece 10 at a top edge 4 thereof. A filter section 16 is designed to be placed over the nose / mouth area and comprises a filter layer for capturing airborne contaminants. At either side of the nose piece 10 the neck gaiter has a left eye contour 14 and a right eye contour 12. The nose piece 10 is configured to follow the contour of the nose. The eye contours 12, 14 each include a shaped section configured so that the top edge 4 of the fabric tube 2 has a contoured profile beside the nose that provides for added spacing of the top edge 4 away from the eyes when in use.

Description

[0001] NECK GAITER

[0002] The present invention relates to a neck gaiter for use as personal protective equipment, as well as to related methods of manufacture. In example embodiments the neck gaiter may provide low burden respiratory protection, such as for professional or private usage.

[0003] A neck gaiter, or face gaiter, is an item of clothing that can be worn around the neck and the lower parts of the face of the user. Some designs also allow for the neck gaiter to be pulled up over the head in order to be similar in form to a balaclava. A neck gaiter is typically a tube of fabric, generally a stretchable fabric, with differing fabrics being used depending on the intended purpose. Neck gaiters are versatile garments that can provide protection for the user from the sun and / or wind and can be used in both warm and cold conditions. They also cover the face and so may be used to hide the identity of the user, preventing the face from being recognised or recorded. As well as being commonly used for weather protection or disguise they can also give some protection to the user from larger airborne debris, droplets and particles such as sand.

[0004] Specialised neck gaiters that provide protection from hazards such as fire and / or cuts are made for use by industrial workers, the emergency services, and military personnel. Products of this type make use of high-performance fabrics such as NomexRTM, PolartecRTMFR and MillikenR™ FR which has fire resistant and antistatic properties, and / or DyneemaR™, which is used as an anti-cut layer. With a layered structure then various different specialised fabrics can be used to combine protective layers along with differing thermal insulation and / or moisture control properties.

[0005] It has been proposed to adapt a neck gaiter by the addition of extra filtering layers adjacent the nose and mouth as disclosed in GB2593564 and US2016213959, for example. These products are intended to use the neck gaiter to provide respiratory protection and / or used as a source control for enhanced resistance to transmission of airborne pathogens from the user to other people nearby. In US2016213959 a mask section with a filter is included at a front section of the garment, along with a nose clip to ensure that the filter is correctly located at / below the nose area. Various fabric structures are used to provide a seal around the mouth / nose area so that the mask section acts as a respirator mask. GB2593564 discloses a neck gaiter that was designed during the period of restrictions prompted by the 2020 SARS-Co-V2 pandemic. It has an intended purpose of improving over other forms of face mask that were widely used during the pandemic to restrict the spread of infection. In some embodiments of GB2593564 the focus is on products where it is ensured that all exhalation passes through the filter section to achieve the required effect for reduction of the risk of infection to other people close to the user. Viewed from a first aspect, the present invention provides a neck gaiter for use as personal protective equipment, the neck gaiter comprising: a hollow fabric tube for encircling the neck and the lower part of the face of a user, wherein the fabric tube includes a top edge for providing the uppermost part of the neck gaiter when in use and a bottom edge for providing the lowermost part of the neck gaiter when in use; a nose piece extending along a part of the top edge of the fabric tube, the nose piece being for location over the bridge of the user’s nose and being configured to follow the contour of the nose; and a filter section spanning an area of the fabric tube that will be located over the user’s mouth and nose when in use, the filter section including a filter layer for capturing airborne contaminants; characterised by: a left eye contour and a right eye contour located on the top edge to either side of the nose, wherein the eye contours each include a shaped section configured so that the top edge of the fabric tube has a contoured profile that provides for added spacing of the top edge away from the eyes when in use.

[0006] With this neck gaiter, in addition to the addition of a filter section and nose piece, the garment is redesigned compared to conventional neck gaiters by the introduction of added eye contours. This allows the nose piece to fit closely to the upper parts of the nose whilst at the same time avoiding obstruction to the user’s eyeline. Such a configuration contrasts to prior art designs in which the top edge of the fabric tube either has no contouring or is shaped in a way that puts the top edge closer to the eyes. For example, a basic traditional neck gaiter stretches freely over the user’s cheeks, leading to a generally straight form beneath the eyes. Typically a neck gaiter of this design is placed relatively low on the nose in order to avoid discomfort or obstruction to the eyes. With prior filtering designs, e.g. as in GB2593564 and US2016213959, the structures added to aid correct fitment of the filter section typically result in a top edge that sits lower on the nose and / or in a straight line beneath the eyes, e.g. due to the form of the nose detail, in clear contrast to the current proposal. It is of particular importance in products for military use that there is a close fit to the upper parts of the nose whilst at the same time there is no restriction to the user’s field of vision. This also has corresponding advantages for emergency services personnel.

[0007] Notably, the neck gaiter of this aspect may be adapted primarily for protection of the user (e.g. from airborne hazards) rather than for prevention of transmission of infection from the user to other nearby people. This means that unlike the product of GB2593564 the neck gaiter disclosed herein need not ensure that all the exhaled air is filtered. The neck gaiter may thus be designed to allow for exhaled air to pass through the fabric tube away from the filter section, such as by having an air permeable fabric at the sides and rear of the fabric tube and / or a less restrictive fabric in a region below the filter section. The design is however configured to provide a high performance in terms of Total Inward Leakage (TIL) and, for example, inhaled air will preferentially pass through the filter section due to its location over the nose and mouth, thereby protecting the user from airborne hazards in the surrounding air. Exhaled air can pass through the filter or may go around it and out through the material of the fabric tube below or to the sides. Note that in this discussion, and elsewhere herein, references to locations such as side and rear are on basis that the nose piece is at the front of the neck gaiter, and references to vertical position (e.g. higher / lower, above / below etc.) are with reference to the normal orientation of the neck gaiter when in use, with the top edge at the top and the bottom edge at the bottom.

[0008] The filter section may provide respiratory protection at a level in between a basic fabric neck gaiter and a gas mask. At the same time, the neck gaiter including the filter section acts as low burden respiratory protection, being as easy to deploy as a conventional neck gaiter The filter section may provide protection against various respiratory hazards such as: sand, construction dust, smoke, exhaust, shooting gases, airborne chemical agents, pathogens and pollen. The filter layer may be held between inner and outer fabric sheets that form an inside surface and an outside surface of the filter section. The filter layer may be replaceable, e.g. to allow for a used filter layer to be removed and replaced with a new filter layer in order to extend the life of the product. Alternatively, the filter layer may be secured in place, e.g. by stitching such as quilting across the filter section, to ensure that it does not shift during use. The filtering effect of the filter layer may be regeneratable by washing and / or by other means, e.g. heating. One of the inner fabric sheet and the outer fabric sheet may be the main material of the fabric tube, and may thus extend in a single sheet out of the filter section and around the remainder of the fabric tube.

[0009] The filter layer is for protecting the user from certain types of airborne hazards, e.g. for capturing airborne contaminants during inhalation. The filter layer may generally comprise one or more layers of fabric material different to the material of the fabric tube. Active filtering materials may be present, e.g. charcoal based filtering or metal organic framework (MOF) type materials, such as materials providing an antibacterial effect. Nanofibre filters may be used. The filter layer may comprise a non-woven fabric, fleece type knitted fabric, or tight knitted fleece fabric. The filter layer may be made from polyester, nylon or cellulose based yarns; fine gauge tight knitted wools; non-woven fabrics made of very fine yarns such as cellulose, split polyester, split nylon and melt blown polypropylene. The filter layer may comprise multiple yarns or blended yarns. The filter section, including the filter layer, may include combinations of materials / constructions known for face masks classified as FFP1 or FFP2 under EN149 in Europe, or face masks classified as N95, R95 or P95 in the US with reference to ASTM F3502-21.

[0010] Advantageously the filter layer, as well as preferably all other fabric parts, can be constructed from materials that are compliant with the US Berry Amendment, in order to permit the neck gaiter to be used for US military purposes. The materials of the outer fabrics and optionally also the filter layer are preferably also selected for compliance with NATO no melt and no drip requirements. The No Melt No Drip (NMND) requirements are widely used for approvals of garments by military bodies and emergency services. NMND introduces requirements for heat resistance for garments, or parts of garments, that may be worn next to or near to the skin and that are not expected to be exposed to direct flame. The materials used for the neck gaiter, e.g. for the fabric tube, may hence be selected based on Berry and / or NATO requirements, including NMND and in addition a Flame Resistance (FR) requirement for the outer layers. Suitable materials may be sourced from the range of technical textiles provided under the Polartec® brand by Polartec, LLC in the US, and the Milliken® brand from Milliken & Company in the US. The fabric tube may comprise Power DryRTMFR, Power GridRTMFR, Wind ProRTMFR, or Power StrechR™ FR. The fabric tube may be a single sheet of a multilayer fabric, e.g. provided as one layer but incorporating multiple functional layers / membranes. For example, the fabric tube may comprise a windstop outer layer combined with a ventilating inner layer. The inner layer may be selected for its thermal properties, e.g. a fabric allowing effective cooling for a summer variant and warmth from thermal insulation for a winter variant.

[0011] The filter section may be configured to capture particles and / or aerosols smaller than 10 pm. In other examples the filter section may be configured to prevent passage of particles and / or aerosols smaller than 5 pm or optionally smaller than 3 pm. The filter section may be configured to capture particles and / or aerosols smaller than 1 pm or optionally smaller than 0.3 pm and advantageously smaller than 0.01 pm. In some examples the filter section may have a performance equivalent to N95, R95 or P95 in the National Institute for Occupational Safety and Health (NIOSH) approval system with reference to ASTM F3502-21. Similarly, the filter section may have a performance equivalent to FFP1 or FFP2 as defined by EN149 in Europe.

[0012] The filter layer may extend across the entire width and height of the filter section, which may be sized to fully cover a typical user’s nose and mouth area as well as extending into a surrounding region. The filter section can extend upward to the top edge and may overlap with the top edge, including overlapping with the nose piece at the top edge. The filter section may be sized to at least cover the full width of the mouth as well as extending from the bridge of the nose to the chin. In some examples the filter section extends downwardly from the top edge of the fabric tube over the mouth and nose and it may extend beyond the chin. However, the filter section need not extend the full height of the neck gaiter and in particular it may not be present at a lower front region of the neck gaiter, e.g. a region that in use will be located well beneath the user’s chin.

[0013] The width of the filter section, i.e. the horizontal dimension when the neck gaiter is in use, may extend over at least 25% of the circumference of the fabric tube, optionally at least 30% and in some cases at least 40% or at least 50%. The width of the filter section may for example be up to 70% of the total circumference. Alternatively, in examples with a smaller filter section design, the width may extend over no more than 50% of circumference of the fabric tube, optionally no more than 40%.

[0014] In some examples, for a neck gaiter of typical dimensions (e.g. an unstretched diameter in the range 50-55 cm), the width of the filter section may be at least 20 cm, preferably at least 25 cm and optionally at least 30 cm. In some examples the width may be no more than 45 cm, preferably no more than 40 cm. For some designs with smaller filter sections the width may be no more than 35 cm, preferably no more than 30 cm.

[0015] The height of the filter section, i.e. the vertical dimension when the neck gaiter is in use and / or the dimension extending between the top edge and bottom edge, may extend as much as the full height of the fabric tube, i.e. the full height between the top edge and the bottom edge. For example the filter section height may be more than 90% of the full height of the fabric tube. A typical design may for example have a height of 30 cm or more for the filter at the front of the gaiter, e.g. measured at the point aligned with the nose piece. As noted above it is not necessary to ensure that all exhaled air is filtered and hence the fabric tube around the lower neck and / or to the sides and rear of the neck gaiter can advantageously be some form of air permeable fabric without any restriction to having a filtering effect.

[0016] Alternatively, in designs with smaller filter sections, the height may be less than the full height of the fabric tube. In that case the height of the filter section may be 70% or less of the full height of the fabric tube, optionally 60% or less. The height of the filter section may for example be 30 cm or less, optionally 25 cm or less.

[0017] For the discussion above the relative widths / heights refer to measurements when the neck gaiter is not being worn and is measured with the fabric in a generally undistorted configuration absent folds or creases, i.e. for height and / or width without the fabric being stretched elastically to fit on the user and with it being set out in a single sheet.

[0018] In the areas of the neck gaiter where the filter section is not present then the neck gaiter may advantageously comprise the fabric tube with no added filtering or restriction on passage of air. This may be provided by a layer of material as discussed above, optionally with folds forming seams at the top edge and bottom edge. Thus, the sides and / or the rear of the neck gaiter may be described as nonfiltered areas of the fabric tube. The front lower portion below the filter section may also be a non-filtered area. A non-filtered area may comprise a single sheet of material, for example a breathable fabric material and / or a multilayer fabric material as described above. This material may be selected for ease of flow of exhaled air as well as for user comfort, e.g. in relation to thermal insulation and / or moisture retention properties. Different materials may be selected for different weather conditions, e.g. for warmth retention and wind blocking for winter use as compared to moisture release and cooling air movement for summer use. In example embodiments it is not a requirement that the rear or the sides of the fabric tube have any added filtering effect, or any restriction on air flow beyond that arising from the fabric of the tube. This fabric may be selected for its properties in relation to thermal insulation, moisture retention / breathability, fire resistance and other characteristics without any regard as to the filtering of airborne contaminants. Possible fabrics are discussed above. The chosen fabric may advantageously be provided in differing colours / patterns, e.g. summer camo, desert camo, winter camo, forest camo, jungle camo, US standard camo, NATO Camo. ARMY, NAVY, Special Forces etc, as well as multi-camo designs.

[0019] The neck gaiter includes left and right eye contours on the top edge to either side of the nose, and these may be at left and right sides of the nose piece, optionally overlapping with the nose piece. The shape of the top edge at the nose piece may form a part of the eye contours, with the main function of the nose piece being linked to the form of the inner surface of the gaiter that fits on the face, whereas the main function of the eye contour is linked to the vertical extent of the top edge below the eyes, i.e. the extent in a dimension generally perpendicular to a contoured shape of the nose piece. The shaped section at each eye contour is a shaped section of the top edge that may take the form of a cut-away extending into the fabric tube in the downward direction of the neck gaiter, i.e. the direction going toward the bottom edge. The eye contour may be formed by cutting and / or folding and sewing the fabric layers of the filter section. Thus, at the eye contour the top edge includes cuts and / or folds in the fabric before final sewing of the top edge in order to give the required shaped section.

[0020] The shaped section may extend into the fabric tube in the downward direction by a distance of at least 5 mm, in some cases at least 10 mm, optionally at least 15 mm. Some examples may have a curvature extending as much as 20 mm or more, e.g. as is done in other garments design for wearing in conjunction with eyewear such as goggles. The extent of the curved section may be measured in comparison to a straight line passing over the eye contour between the top edge at the centre of the nose piece and the top edge at a location to the side of the neck gaiter beyond the eye contour. This straight line may in some cases be a continuance of a straight portion of the top edge that extends from the eye contour to the rear of the neck gaiter. Alternatively, or additionally, the shaped section may take the form of a reduced thickness of the top edge at a location beneath the eye.

[0021] The nose piece is configured to follow the contour of the nose, i.e. in relation to an internal shape of the neck gaiter that is placed on the face. The nose piece may comprise multiple elements for placement at different parts of the nose. This means that when it is located over the bridge of the user’s nose then it aids in keeping the neck gaiter in the correct position for proper use. In addition the nose piece aids in ensuring that during inhalation then air movement between the face and the top edge is restricted, ideally keeping this to a minimum by making the resistance to air movement passing around the top edge greater than the resistance to air movement passing through the filter section. In this way the nose piece aids in ensuring that inhaled air is filtered.

[0022] The nose piece may comprise one or more horizontal element(s) configured to follow the contour of the nose in the direction across the width of the user’s face, e.g. by means of an internal contouring on the surface of the nose piece that confronts the user’s face. The nose piece may comprise a central indented part for placement on the bridge of the nose as well as left and right outer pads for placement with one on either side of the user’s nose. The outer pads may be outwardly curved, i.e. extending outward from the material of the fabric tube in order to fill any gap that may otherwise arise between the nose / face and the fabric tube at either side of the nose. The outer pads may be convex pads, such as pads having a convex shape when viewed in one or more cross-section.

[0023] There may be one or more horizontal element(s) with a suitably contoured or curved form, such as a curved stiffener (e.g. a wire, metal strip, or other plastically deformable element) and / or nose pads (such as the outer pads, e.g. including foam padding such as PU foam). The plastically deformable element may be a nose clip, e.g. a metal strip.

[0024] The nose piece may comprise a plastically deformable element configured to follow the contour of the nose in the direction across the width of the user’s face, wherein the plastically deformable element is for providing at least a part of the shaped section of the eye contours. There may be one or more plastically deformable elements for providing at least a part of the shaped section of the eye contours.

[0025] In the case of nose pads then the contoured form may be provided by a central indented part for placement on the bridge of the nose, with two outer pads (e.g. convex pads) for placement with one on either side of the user’s nose. The outer pads are advantageously thicker than the remainder of the top edge due to added padding, e.g. foam padding, whereas the central indented part has a lesser thickness than the outer pads. The thickness of the central indented part may be less than 50% of the thickness of the outer pads. The central indented part may have no added padding compared to the main part of the top edge at the filter section, i.e. the top edge in a region outside of the nose piece and absent the contoured form for fitting to the nose. Thus, the only added padding may be in the two outer pads.

[0026] The outer pads may have a maximum thickness of 0.5 cm or more, e.g. a maximum thickness of about 1 cm. The thickness may taper toward one or both of the ends of the outer parts. The outer pads may have a total length (i.e. an extent across the face parallel to the top edge of the fabric tube) of at least 5 cm and / or less than 10 cm, e.g. a length of about 6.5 cm.

[0027] In example embodiments the central indented part has an unpadded width of 2 cm or more, for example about 2.5 cm. This means that the central indented part can fit closely across the bridge of the nose while the outer pads will fit the inward curves of the face at either side of the nose. This provides the required curved profile for the inner surface of the nose piece to configure it to follow the contour of the nose.

[0028] There may be stitching separating the central indented part and the outer pads and / or at the outer ends of the outer pads. The stitching may pass through the full thickness of the top edge and extend vertically across the top edge. This can aid the comfort of fit and / or the sealing effect of the nose pad by aiding flexibility of the outer pads about the central indented part. Stitching at the outer ends of the outer pads may also give a reduction in thickness of the top edge beneath the eye, which can aid vision and may form part of the eye contour.

[0029] In the example embodiments the plastically deformable element(s) allow the shape and curvature of the outer pads to be adjusted to better fit the user’s face. Adjustment of the plastically deformable element(s), e.g. by bending or twisting, may provide at least a part of the shaped section of the eye contours via a corresponding adjustment to the shape of the neck gaiter, e.g. a reshaping of the nose piece. This may for example involve a deformation of the fabric of the top edge, a deformation of the outer pads, a deformation of the central indented part and / or a movement of two or more of those parts relative to one another.

[0030] The outer pads may include a single plastically deformable element or more than one plastically deformable elements, e.g. a nose clip, for example a metal strip or wire. The one or more plastically deformable elements may be provided within the outer pads or adjacent to them, e.g. along the fabric above the outer pads.

[0031] A single plastically deformable element may extend into or adjacent to both outer pads and across the central indented part, e.g. similar to a nose clip as provided by a metal strip on known face masks. Alternatively, there may be one or more plastically deformable element(s) in each of the A combination of elastic padding and one or more plastically deformable element(s) has been found to allow a standard size to be adjusted to fit a wide range of users. The plastically deformable element(s) are used to provide at least a part of the shaped section of the eye contours. In this case the plastically deformable element(s) may be configured such that the outer pads are located vertically away from the eyes, and / or such that the top edge outward of the outer pads is directed downwardly on the face. The outer surface of the nose piece may form a continuous curve across the nose when in use, so that force from tension in the top edge (e.g. from elastic deformation of the fabric tube and or elasticated elements of the top edge) is not concentrated on the bridge of the nose but rather is spread across the nose piece and conveyed to the face via the internal curvature of the nose piece and / or the curvature of the eye contours, such as by means of forces passing through the outer pads and / or the plastically deformable elements as mentioned above.

[0032] The nose pad(s) (e.g. the outer pads and / or the central indented part) may comprise so-called memory foam or it may be provided in a form that can be moulded and cured to fit the user. The neck gaiter may be provided in differing fits having nose pads of varying sizes and shapes to fit different facial contours. Additively manufactured materials may be used to give a bespoke fit for the user.

[0033] The nose piece may comprise a vertical element for location along the bridge of the nose. The vertical element may be configured to extend from the top edge toward the tip of the nose, optionally terminating after the tip of the nose. The vertical element may for example be at least 40 mm long or at least 50 mm long, e.g. about 60 mm long. This can aid in keeping a spacing between the filter section and the user’s face, e.g. so that the filter section is kept spaced apart from the nostrils and lips. The vertical element may be a reinforced or stiffened section of fabric, e.g. a stiff webbing material. It may comprise a reinforcing element such as a wire, a metal strip, or a plastic stiffener. In some examples the vertical element comprises a piece of stiffer fabric, such as a piece of webbing, that is located along the nose area and advantageously extends beyond the tip of the nose in order to keep the material of the filter section spaced apart from the mouth.

[0034] The neck gaiter may comprise a fabric structure for aiding secure placement of the nose piece at the nose. There may be darts or inserts to allow for a better fit at the tip of the nose. In some examples there is a cut nose as found in neoprene face masks, with the resulting hole filled in with an inserted fabric part of the same composition as the filter section.

[0035] When in use the top edge of the neck gaiter may encircle the user’s head at a location generally aligned with the ears, whereas the bottom edge may sit around the collar region of the user. The top edge may be elasticated in order that it is in tension when worn. Thus, there may be an elasticated region providing for elasticity in addition to the elasticity of the fabric used for the hollow fabric tube. This aids in securing the neck gaiter to the face as well as ensuring that the nose piece fits tightly to avoid a risk of inhaled air passing between the top edge and the skin, i.e. without being filtered through the filter section. The top edge may include an elasticated section at the rear of the neck gaiter, e.g. formed by stitches of elasticated material and / or incorporation of a band of flat elastic material. The bottom edge may be intended to be tucked into the user’s clothing, e.g. into a collar of an upper body garment such as a t-shirt or sweatshirt, which can aid the seal for the filtering effect as well as keeping the garment in place during motion. The bottom edge may be formed without additional elastic elements and thus may be only as elastic as the material that is used for the fabric tube. The bottom edge may drape relatively loosely at the front in order that it remains in contact with the user even during motion, e.g. tilting / turning movement of the head, or up / down acceleration of the user during running. The fabric tube may be designed to encircle the neck without any large folds at the front, e.g. as for neoprene garments, but may be permitted to gather in folds or pleats at the back. In some examples the fabric tube has a varying height, e.g. as discussed below, and in this case it may be shaped and sized to extend, when worn, generally in a single unfolded sheet at the front from the top edge placed over the nose and around the head to the bottom edge that encircles the user in contact with the rear of the neck, the tops of the shoulders, and the chest. Each of the bottom edge and the top edge may comprise a double layer of the material of the fabric tube, e.g. a hemmed edge.

[0036] The bottom edge is spaced apart from the top edge by the height of the fabric tube, and this height varies at least by virtue of the eye contours and / or the nose piece. There may be additional variations in the height of the fabric tube, such as increases and reductions in length at different points around the neck to ensure a good fit, which aids in keeping the neck gaiter in place during movement of the user. For example, the height of the fabric tube may be larger at the front and smaller at the rear in view of the fact that the fabric may need to span a longer distance beneath the chin to reach the collar / chest than the distance that is needed to reach the rear of the neck. The bottom edge may be provided with a curve at the sides of the neck gaiter for fitting closely over the user’s shoulders without the need for the fabric to be folded or hang over itself.

[0037] The top edge may be designed to be placed either over the ear or under the ear without influencing the positioning of the nose piece on the face. This allows the user to wear the neck gaiter in a comfortable way, including when wearing a helmet, whilst maintain the correct placement of the filter section. In addition the design allows for use of hearing protection or communication equipment by permitting the gaiter to be placed under the ears to avoid obstruction with other ear mounted equipment. The eye contours may aid in enhancing ease of movement of the top edge to below the ears since in some configurations they may encourage the top edge to sit lower on the sides of the face. The elasticity of the fabric tube and of the top edge, including added elastic elements at the rear, also aids in allowing repositioning of the top edge over or beneath the ears.

[0038] Advantageously the side parts of the top edge do not comprise any protruding or hard parts, e.g. straps, buckles or clips. This avoids creating incompatibility or discomfort in relation to wearing a helmet. In some examples the side parts comprise only the fabric of the fabric tube, optionally a double layer in a hem. The neck gaiter as a whole may comprise no protruding or hard parts, e.g. straps, buckles or clips, and may be fitted to the user purely by its elasticated nature. Optionally, the top edge comprises an elasticated rear section along with a hook and loop fastener for adjusting tension in the top edge. This gives a very low threshold for deployment and makes it easy for the user to protect themselves from airborne contaminants and other airborne hazards, as well as other risks such as fire or weather conditions.

[0039] Viewed from a second aspect the present invention provides a method of manufacture of a neck gaiter for use as personal protective equipment, wherein the neck gaiter is as described in the first aspect. Such a method of manufacture may comprise: forming the fabric tube with a top edge and bottom edge; attaching the nose piece at the top edge; and providing the filter section; wherein forming the fabric tube with the top edge includes providing the top edge with the left and right eye contours.

[0040] The method may be for manufacture of a neck gaiter that has any of the additional features that are discussed above for the first aspect.

[0041] The method of manufacture may differ compared to manufacture of conventional neck gaiters by added steps for the introduction of eye contours. As discussed above the shaped section at each eye contour may take the form of a cut-away extending into the fabric tube in the downward direction of the neck gaiter. The method may include cutting the fabric tube into a curved shape before forming the top edge, e.g. before hemming the top edge.

[0042] The filter section may be provided with a filter layer between inner and outer fabric sheets that form an inside surface and an outside surface of the filter section. The method may include securing the filter layer in place, e.g. by stitching such as quilting across the filter section.

[0043] The nose piece is configured to follow the contour of the nose and it is attached at the top edge in the location where the neck gaiter will fit on the nose. The nose piece may comprise one more horizontal element(s) such as one or more plastically deformable element(s) and / or a pair of nose pads (e.g. outer pads as discussed above), and the method may include attaching the horizontal element(s) to the top edge, e.g. by adhesive or by stitching. The horizontal element(s) may be enclosed within inner and outer sheets of the filter section. The method may include forming the nose piece with a contoured shape as discussed above, optionally forming this for a bespoke fit to the shape of the user’s nose, e.g. by means of fitting process including moulding and curing the pad material or by additive manufacture after measuring the shape of the user’s nose. The method may include using the plastically deformable element(s) to provide at least a part of the shaped section of the eye contours, e.g. by deforming the plastically deformable element(s) in order to thereby adjust the form of the top edge and / or the nose piece.

[0044] The method can include adding an elasticated region at the top edge, e.g. at a rear part thereof. As discussed above this elasticated region provides for elasticity in addition to the elasticity of the fabric used for the hollow fabric tube. The elasticated section may be formed by stitches of elasticated material and / or incorporation of flat elastic. Optionally the method may include fitting the top edge with a hook and loop fastener for adjusting tension in the top edge.

[0045] Each of the bottom edge and the top edge may be made using a double layer of the material of the fabric tube, e.g. by folding and stitching to form a hemmed edge.

[0046] The method may comprise forming variations in the height of the fabric tube, such as providing increases and reductions in length at different points around the neck as discussed above.

[0047] Certain example embodiments will now be described by way of example only and with reference to the accompanying drawings in which:

[0048] Figures 1 to 3 show different views of a first example of a neck gaiter;

[0049] Figures 4 to 6 show different views of a second example of a neck gaiter;

[0050] Figure 7 shows an example of a nose pad for the neck gaiter;

[0051] Figure 8 is a schematic cross-sectional diagram of a possible construction for a filter section;

[0052] Figures 9A and 9B show details of the construction of a nose piece;

[0053] Figure 10 to 12 show a third example of a neck gaiter in different views; and

[0054] Figure 13 shows a typical form of the neck gaiter when worn.

[0055] A front elevation of a user wearing a neck gaiter is seen in Figure 1, with Figure 2 showing a side view of the same neck gaiter and user, and Figure 3 illustrating the neck gaiter from the rear with the user removed to show added details. Another example of a neck gaiter is shown in Figures 3 to 6, once again with a front, side and rear view of the neck gaiter in the “as worn” configuration. In these Figures the neck gaiter is shown in an idealised form, and it will be realised that when worn in the real world there will be drapes and folds in the fabric, e.g. similar to those shown in Figure 13.

[0056] The neck gaiter includes a hollow fabric tube 2 that fits around the neck of the user and the lower part of the face of a user. A top edge 4 forms the uppermost part of the neck gaiter when in use and a bottom edge 6 provides the lowermost part. The top edge 4 encircles the user’s head at about the same height as the ears and it holds the neck gaiter in place due to the inherent elasticity of the fabric as well as an added elasticated section 8 at the rear of the gaiter. The elasticated section 8 is formed by added stitching of an elastic thread and / or by flat elastic held within the hem about the top edge 4. Optionally, as shown in Figures 5 and 6, the neck gaiter can also include a hook and loop side pull 9 for adjusting the tension in the top edge 4. In this case it is preferred to use a soft / thin hook and loop material in order to reduce the noise when it is released. At the front of the top edge 4 is a nose piece 10, which extends along a part of the top edge 4 over the bridge of the user’s nose when the neck gaiter is being worn. The nose piece 10 is configured to follow the contour of the nose and in this example the nose piece 10 has padding that can include a contoured profile as discussed in more detail below with reference to Figure 7. This can be achieved via the use of outer pads 24 located to either side of the centre of the nose piece 10 as seen in Figure 6.

[0057] At the front of the neck gaiter is a filter section 16 spanning an area of the fabric tube 2 that will be located over the user’s mouth and nose when in use. The filter section 16 includes an internal filter layer for capturing airborne contaminants as described in more detail below with reference to Figure 8. The filter section 16 sits below the nose piece 10 and extends over the front of the fabric tube 2. In the example of Figures 1 to 3 the filter section 16, shown with shading, extends over a large part of the front of the fabric tube 2 but not over its full vertical extent. In the example of Figures 4 to 6 the filter section 16 is larger in area and spans the full height of the fabric tube 2 as well as the full width from side-to-side between the ears, in this case between the stitching close to the ears.

[0058] At either side of the nose piece 10 there is a left eye contour 14 and a right eye contour 12. These are located on the top edge 4 of the fabric tube 2 and they include a shaped section forming a contoured profile beside the nose piece 10. This provides for added spacing of the top edge 4 away from the user’s eyes. For example, as seen in in the left side view of Figure 2, the left eye contour 14 can include a cutaway where the top edge 4 curves downward away from the eye to a larger distance than if the top edge 4 were a simple elastic fabric edge. The shaped section may be stiffened by added stitching and / or by a stiffener incorporated into / along the top edge 4. The shaped section of the eye contours 12, 14 can be provided, at least in part, by stiffening elements in the nose piece 10, such as a plastically deformable element 25 (e.g. a metal wire or metal strip) as seen in Figure 6 and Figure 12 for example.

[0059] The neck gaiter of Figures 1 to 3 also has a cut nose 18 with an added insert of fabric to allow for a better fit at the tip of the nose. This can be seen on the outside in Figures 1 and 2, and from the inside in Figure 3. The cut nose 18 provides a fabric structure for aiding secure placement of the nose piece at the nose. It can have a similar placement and form to the cut nose used in neoprene face masks, with the resulting hole filled in with an inserted fabric part of the same composition as the filter section 16. The cut nose 18 can be incorporated into the nose piece 10 either by simple use of the fabric of the filter section 16, or alternatively by an added strengthening or stiffening, e.g. placed to run along the bridge of the nose.

[0060] Alternatively, there may be added strengthening or stiffening at the nose piece 10 without the cut nose 18, e.g. using a construction as seen in Figures 4 to 6, which may be as explained in more detail below with reference to Figures 9A and 9B.

[0061] As noted above the nose piece 10 has padding that includes a curved profile and an example of this is shown in Figure 7. The nose piece 10 shown in Figure 7 could be incorporated into a neck gaiter as shown in Figures 1 to 3 and / or Figures 4 to 6 and is a part of the neck gaiter as shown in Figures 10 to 12, as described further below. The nose piece 10 includes a set of horizontal elements 20, which sit horizontally on the user’s nose when the neck gaiter is worn. The horizontal elements 20 are flexible, e.g. formed of fabric and padded with an elastic foam material such as PU foam. They are configured to follow the contour of the nose by means of an internal contour that is placed against the nose. The horizontal elements 20 include a central indented part 22 for placement on the bridge of the nose, with two outer pads 24 for placement with one on either side of the user’s nose. The outer surface 26 of the horizontal elements 20 may form a continuous curve across the nose. The horizontal elements include stiffening such as a plastically deformable element 25, e.g. above the pads 24 as shown in Figures 6 and 9B or otherwise incorporated within or adjacent pads 24 of the type shown in the nose piece 10 of Figure 7. The nose piece 10 can be formed inside of the top edge 4 of the fabric tube 2 at the outer surface 26. When the top edge 4 is pulled taut across the nose then force from tension in the top edge 4 will bend the horizontal elements 20 of the nose piece 10 at the central indented part 22 as well as at the stitched joints either side thereof, which will push the pads 24 against the sides of the nose. This ensures a good fit of the top edge 4, restricting air flow around the top of the neck gaiter. It also aids comfort by avoiding a concentrated force on the nose bridge. In addition to padding the outer pads 24 are advantageously provided along with plastically deformable elements 25, such as one or more wire(s) or metal strip(s), which allow the user to form the pads 24 into a required shape to better fit to the curvature of their face. As well as this there may be silicone strips 27 on the pads 24 or aligned with the plastically deformable elements, e.g. as shown in Figure 6 or Figure 7, for location against the skin and for removably adhering to the skin, i.e. restricting a sliding movement but allowing the neck gaiter to be pulled away from the face to remove it. Suitable strips 27 may for example be formed by printing. These silicone strips 27 aid in positioning the nose piece 10 for comfort and good sealing of the neck gaiter as well as ensuring good spacing between the top edge and the user’s eyes. Similar silicone material may be provided in a strip around the rear of the neck gaiter at the top edge 4, e.g. at the location of the elasticated section 8. The plastically deformable elements 25 may be internal to the pads 24 or may be provided beside / adjacent to them. The plastically deformable elements 25 can provide a stiff and bendable horizontal element that can be used to shape the nose piece 10 and aid in keeping the required shape / position of the eye contours 12, 14. The plastically deformable elements 25 can take the form of a metal wire or strip. The stitching at either side of the pads 24 also aids in forming the eye contours 12, 14.

[0062] The filter section 16 is shown shaded in Figures 1 to 3 and Figures 10 to 12. In Figures 4 to 6 the filter section 16 spans across the face between the side stitches that are adjacent to the ears. Figure 8 is a diagram showing the layered structure of the filter section 16. The material of the fabric tube 2 provides one sheet of the filter section 16, typically the outer sheet. A filter layer 28 is held between the outer sheet and an added inner sheet 30. In some examples the filter section is quilted, with the internal filter layer 28 hence being attached to both the fabric tube 2 and the inner sheet 30 by a pattern of stitches that passes through the full width of the filter section 16. As discussed above the fabric tube 2 can be a single sheet of a multilayer material, which may comprise materials such as NomexR™, PolartecR™ FR, MillikenR™ FR, and / or DyneemaRTM, for example Power DryRTMFR, Power GridRTMFR, Wind ProRTMFR, or Power StretchRTMFR. The inner sheet 30 of the filter section 16 can be a similar multilayer material, but typically is a different grade of multilayer material selected for comfort and / or for properties such as moisture handling abilities. The filter layer 28 provides the main filtering function of the filter section 16. The material of the filter layer 28 can be as discussed above, and thus the filter section 16 may include combinations of materials / constructions known for face masks classified as FFP1, FFP2 or FFP3.

[0063] Figures 9 A and 9B show the construction of a nose piece 10, e.g. as used in the example of Figures 4 to 6. It will of course be appreciated that the same advantages can be achieved by using a similar nose piece 10 in the neck gaiter of Figures 1 to 3 or Figures 10 to 13. Figure 9A is a front view showing the shape of the nose piece along with a reinforced bridge section 32, which in this example comprises a 60mm length of stiff webbing material 32. Figure 9B is a cross-section along the line of this stiff webbing material 32 showing the internal layer structure and the relative location of the horizontal elements. In this example the filter section 16 comprises a filter layer 28 in between the fabric tube 2 and the inner sheet 30 as discussed above in relation to Figure 8. The stiff webbing material 32 is placed at the nose piece outside of the filter layer 28. Inside of the filter layer 28 is the central indented part 22 of the horizontal elements 20, which in this case is a foam pad 22 that would be in between the two outer pads 24 (not visible in this Figure). A plastically deformable element 25 is located above the central intended part 22. In this case the plastically deformable element 25 is a single piece spanning across the nose, and in this example it is a 6 mm wide metal strip that is placed about 10 mm from the end of the top edge 4. The plastically deformable element 25 may for example be similar in shape and material type to deformable nose clips known for use in surgical masks and the like.

[0064] Another example of a neck gaiter is shown in Figures 10 to 13. Figures 10 to 12 are diagrams showing the neck gaiter in an idealised form, and they which including a front perspective view with the user shown as well as a rear perspective view and rear elevation that omit the user but shown the garment in the form it takes when worn. Figure 13 shows the neck gaiter in a real -world form when worn. It will be appreciated that there will be folds and gathered regions of the fabric, especially at the rear, which are important to ensure a good fit for varying body shapes as well as to maintain a good fit even during movement. However, the neck gaiter is designed to avoid unnecessary folds at the front, where the fabric of the filter section hangs in generally one unfolded part when the user is in an upright position. In this example the neck gaiter includes a fabric tube 2 with a top edge 4, a bottom edge 6 and an elasticated section 8 similar to that of Figures 1 to 3 and Figures 4 to 6, but with a different stitching detail and a differing form for the eye contours 12, 14 and nose piece 10. The nose piece 10 can include horizontal elements 20 with two outer pads 24 of the type shown in Figure 7 as well as a plastically deformable element 25 as seen in Figure 6. The placement of these horizontal elements 20 at the front inner part of the neck gaiter is shown in Figures 11 and 12. In this case the outer pads 24 are at either side of the nose and may extend upward to the top edge 4 of the neck gaiter, whilst the plastically deformable element 25 extends across the nose between the two pads 24. The filter section 16 can have a layered structure as seen in Figures 8 and 9B, but it has a different shape and extent in this example as compared to Figures 1 to 3 or Figures 4 to 6. Another difference compared to Figures 1 to 3 is that this example does not include a cut nose 18. However, it does have a reinforced bridge section 32 for placement along the bridge of the user’s nose and this may be similar to that seen in Figures 9A and 9B. The reinforced bridge section 32 may comprise added stitching or other strengthening of the fabric to maintain a desired shape. It could incorporate an added vertical element such as a wire, metal strip, or plastic stiffener.

[0065] As seen in the examples the fabric tube 2 is designed to encircle the neck with the bottom edge 6 fitted against the user’s body. The bottom edge 6 is spaced apart from the top edge 4 by the height of the fabric tube 2, and this height varies around the circumference of the garment in order to allow the bottom edge 6 to fit to the user’s body at the back of the neck, over the shoulders to either side of the neck, and at the top of the chest. Thus, the height of the fabric tube 2 is larger at the front and smaller at the rear because the fabric spans a longer distance beneath the chin to reach the collar / chest than the distance needed to reach the top of the user’s back at the rear of the neck. The bottom edge 6 also has curves at each of the sides of the neck gaiter so that it fits closely over the user’s shoulders.

Claims

CLAIMS:

1. A neck gaiter for use as personal protective equipment, the neck gaiter comprising: a hollow fabric tube (2) for encircling the neck and the lower part of the face of a user, wherein the fabric tube (2) includes a top edge (4) for providing the uppermost part of the neck gaiter when in use and a bottom edge (6) for providing the lowermost part of the neck gaiter when in use; a nose piece (10) extending along a part of the top edge (4) of the fabric tube (2), the nose piece (10) being for location over the bridge of the user’s nose and being configured to follow the contour of the nose; and a filter section (16) spanning an area of the fabric tube (2) that will be located over the user’s mouth and nose when in use, the filter section (16) including a filter layer (28) for capturing airborne contaminants; characterised by: a left eye contour (14) and a right eye contour (12) located on the top edge (4) to either side of the nose, wherein the eye contours (12, 14) each include a shaped section configured so that the top edge of the fabric tube (2) has a contoured profile that provides for added spacing of the top edge (4) away from the eyes when in use.

2. A neck gaiter as claimed in claim 1, wherein the shaped section at each eye contour (12, 14) includes cuts and / or folds in the fabric before sewing of the top edge (4) in order to give the form of a cut-away extending into the fabric tube (2) in the downward direction of the neck gaiter.

3. A neck gaiter as claimed in claim 1 or 2, wherein the shaped section of the eye contours (12, 14) extends into the fabric tube (2) in the downward direction by a distance of at least 5 mm.

4. A neck gaiter as claimed in claim 1, 2 or 3, wherein the nose piece (10) comprises one or more plastically deformable element (25) configured to follow the contour of the nose in the direction across the width of the user’s face, wherein the plastically deformable element (25) is for providing at least a part of the shaped section of the eye contours (12, 14).

5. A neck gaiter as claimed in any preceding claim, wherein the nose piece (10) comprises a central indented part (22) for placement on the bridge of the nose as well as left and right pads (24) for placement with one on either side of the user’s nose.

6. A neck gaiter as claimed in claim 5, wherein the plastically deformable element(s) allow the shape and curvature of the pads (24) to be adjusted.

7. A neck gaiter as claimed in claim 5 or 6, comprising a plastically deformable element (25) extending across the central indented part (22) in order to act as a nose clip.

8. A neck gaiter as claimed in any of claims 5 to 7, wherein the central indented part (22) has no added padding compared to the main part of the top edge (4) at the filter section (16).

9. A neck gaiter as claimed in any of claims 5 to 8, comprising stitching separating the central indented part (22) and the outer pads (24) and / or stitching at the outer ends of the pads (24), with this stitching passing through the full thickness of the top edge (4) and extending vertically across the top edge (4).

10. A neck gaiter as claimed in any preceding claim, wherein the nose piece (10) comprises a piece of webbing (32) configured to be located along the nose area extending beyond the tip of the nose when the neck gaiter is worn.

11. A neck gaiter as claimed in any preceding claim, wherein the bottom edge (6) is spaced apart from the top edge (4) by the height of the fabric tube (2), with this height varying at different points around the neck, wherein the height of the fabric tube is larger at the front and smaller at the rear, and wherein at each side of the neck gaiter the bottom edge (6) comprises a curve for fitting over the user’s shoulders.

12. A neck gaiter as claimed in any preceding claim, wherein the neck gaiter is designed to allow for exhaled air to pass through the fabric tube (2) away from the filter section (16).

13. A neck gaiter as claimed in any preceding claim, wherein the fabric tube comprises a permeable multilayer fabric including a windstop outer layer (2) combined with a ventilating inner layer (30).

14. A neck gaiter as claimed in any preceding claim, wherein the filter section (16) is configured to provide protection against respiratory hazards including: sand, construction dust, smoke, exhaust, shooting gases, airborne chemical agents, pathogens and pollen.

15. A neck gaiter as claimed in any preceding claim, wherein the top edge (4) is designed to be placed either over the ear or under the ear without influencing thepositioning of the nose piece (10) on the face, and wherein the side parts of the top edge (4) do not comprise any protruding or hard parts such as straps, buckles or clips.

16. A neck gaiter as claimed in claim 15, wherein the top edge (4) comprises an elasticated rear section (8) along with a hook and loop fastener (9) for adjusting tension in the top edge (4).

17. A method of manufacture of a neck gaiter as claimed in any preceding claim, the method comprising: forming the fabric tube (2) with a top edge (4) and bottom edge (6); attaching the nose piece (10) at the top edge; and providing the filter section (16); wherein forming the fabric tube with the top edge (4) includes providing the top edge (4) with the left and right eye contours (14, 12).

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