Note: Descriptions are shown in the official language in which they were submitted.
CA 3,096,379
CPST Ref: 11271/00007
1 PERIMETER SEAL FOR A FACE MASK
2
3 CROSS-REFERENCE TO RELATED APPLICATION
4 [0001] This application claims priority to: U.S. Application
Serial No. 62/993,450, filed
March 23, 2020; U.S. Application Serial No. 63/005,073, filed April 3, 2020;
U.S. Application
6 Serial No. 16/849,203, filed April 15, 2020; and U.S. Application Serial
No. 17/064,377, filed
7 October 6, 2020.
8
9 FIELD OF DISCLOSURE
[0002] The present disclosure relates generally to face masks and, in
particular, to face
11 masks with a perimeter seal.
12
13 BACKGROUND
14 [0003] Face masks used in the health industry are generally of
two types: surgical masks
intended to act primarily as a barrier to splashes, droplets and spit and to
protect the patient from
16 infection, and respirators used by healthcare workers and others as
personal protection
17 equipment to additionally enhance protection of the face mask wearer
from exposure to
18 infection. Both are constructed with filtering media that covers the
nose and mouth of the
19 wearer, so that any air passing in or out of the wearer's mouth and nose
through the filtering
media is filtered from biological aerosols such as bacteria and viruses.
Surgical masks do not
21 typically have a seal to seal a perimeter of the face mask to one's
face. A respirator is a face
22 mask constructed with filtering media having a high filtration
efficiency and an added seal to
CPST Doc: 330145.1 1
Date Recue/Date Received 2021-01-26
CA Application
CPST Ref: 11271/00007
1 seal the perimeter of the filter media tight to the wearer's face. The
seal is commonly built into
2 the face mask by using an elasticized border, silicone or rubberized
gaskets, or by other means,
3 to minimize or preferably eliminate any flow of unfiltered air through
gaps between the wearer's
4 face and the periphery of the filtering media.
[0004] US 7,017,577 discloses using pressure-sensitive adhesive applied
directly to the
6 perimeter of a non-sealed face mask and then adhering the mask directly
to the wearer's skin.
7 The adhesive may be directly applied from a tube, or strips of tape may
be adhered to the face
8 mask perimeter. The strips of tape have a release layer that is peeled
off after the tape is applied
9 to the perimeter of the mask, revealing an adhesive that is then sealed
directly to the face.
[0005] For the protection of healthcare workers, there is a need for a
method and device
11 for quickly converting a face mask manufactured with no seal (also
referred to herein as a "non-
12 sealed" face mask) to a sealed face mask, or respirator, in the event
that pre-manufactured
13 respirators are not readily available. There is also a need for a device
for converting a non-sealed
14 face mask to a sealed face mask that can be efficiently and quickly
manufactured.
SUMMARY
16 [0006] Features of the disclosure will become apparent from the
following detailed
17 description considered in conjunction with the accompanying drawings. It
is to be understood,
18 however, that the drawings are designed as an illustration only and not
as a definition of the
19 limits of this disclosure.
[0007] The present disclosure is directed to a method and device for
providing a
21 perimeter seal for a face mask and for quickly converting an existing
pre-manufactured non-
22 sealed face mask to a sealed face mask for enhanced protection of the
wearer from biological
CPST Doc: 299465.1 2
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 aerosols. The present disclosure is also directed to a method for
manufacturing a perimeter seal
2 for a face mask.
3 [0008] The present disclosure is also directed to a perimeter
seal device for forming a
4 perimeter seal for a face mask, which includes a top release liner, an
adhesive layer, and a
bottom release liner, wherein the adhesive layer is sandwiched between the top
release liner and
6 the bottom release liner. The top release liner includes a perimeter
portion and a central portion
7 defined by a perimeter cut therebetween. The adhesive layer includes a
carrier with an upper
8 surface and a lower surface, with a pressure-sensitive adhesive coated on
each of the upper
9 surface and the lower surface. The adhesive layer also includes a
perimeter portion and a central
portion aligned with the perimeter portion and the central portion of the top
release liner,
11 respectively. The perimeter portion of the adhesive layer is separable
from each of the central
12 portion of the adhesive layer, the top release liner, and the bottom
release liner to form a
13 perimeter seal for a face mask.
14 [0009] In aspects, the perimeter seal device includes a
perimeter cut extending from an
upper surface of the top release liner through the lower surface of the
adhesive layer, and not
16 through the bottom release liner.
17 [0010] In aspects, the bottom release liner adhesive layer
includes a peel portion that
18 extends beyond a perimeter of the adhesive layer, wherein the peel
portion is adhesive-free.
19 [0011] The top release liner further includes, in aspects, a
cut therethrough, which does not
extend through the adhesive layer, to provide a crack-and-peel edge, the cut
and crack-and-peel
21 edge extending from a perimetral edge of the top release liner to the
perimeter cut.
CPST Doc: 299465.1 3
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0012] Each of the top release liner, the adhesive layer, and
the bottom release liner may
2 be rectangular-shaped, in further aspects, with the peel portion
extending beyond the perimeter of
3 the adhesive layer along at least one edge of the adhesive layer.
4 [0013] In some aspects, the bottom release liner is centered to
the upper release liner and
the adhesive layer, with the peel portion extending beyond two edges of the
adhesive layer.
6 [0014] In some aspects, each of the top release liner, the
adhesive layer, and the bottom
7 release liner is oval-shaped.
8 [0015] In aspects, at least the perimeter portion of the
adhesive layer provides a perimetral
9 strip configured and shaped to provide a perimeter seal on the periphery
of a face mask to which
the perimeter seal is adhered.
11 [0016] In aspects, the carrier providing the adhesive layer is
a stretchable plastic film.
12 [0017] In further aspects, each of the top release liner and
the bottom release liner
13 includes one of a paper sheet and a plastic film, silicone-coated on at
least one side, wherein the
14 top release liner is silicone-coated on a lower surface, and the bottom
release liner is silicone-
coated on an upper surface.
16 [0018] In additional aspects, one of an upper surface of the
top release liner and a bottom
17 surface of the bottom release liner may include a two-dimensional bar
code printed thereon.
18 [0019] In aspects, the bottom release liner includes a peel
portion that extends beyond a
19 perimeter of the adhesive layer, the top release liner is silicone-
coated on a lower surface, and the
bottom release liner is silicone-coated on an upper surface, and the carrier
of the adhesive layer
21 is formed of polyethylene and the pressure-sensitive adhesive includes a
medical grade acrylic
CPST Doc: 299465.1 4
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0020] The perimeter seal device is configured to adhere either
one of the upper surface
2 and the lower surface of the perimeter portion of the adhesive layer to
the face mask to form the
3 perimeter seal on the face mask, in accordance with methods of the
present disclosure.
4 [0021] The present disclosure is also directed to a method for
forming a face mask with a
perimeter seal using an embodiment of the perimeter seal device of the
disclosure, the method
6 including exposing the pressure-sensitive adhesive on the lower surface
of a perimeter portion of
7 the adhesive layer, including peeling intact a two-layer perimetral strip
portion of the perimeter
8 seal device off of the bottom release liner. The two-layer perimetral
strip portion includes the
9 perimeter portion of the top release liner layered on the perimeter
portion of the adhesive layer.
The perimeter portion of the adhesive layer forms the perimeter seal for
attaching to a face mask.
11 [0022] In aspects, the method includes adhering, by pressing,
the two-layer perimetral
12 strip portion onto a periphery of a user-facing side of the face mask
via the pressure-sensitive
13 adhesive on the lower surface of the perimeter portion of the adhesive
layer; and removing the
14 perimeter portion of the top release liner to expose the pressure-
sensitive adhesive on the upper
surface of the adhesive layer.
16 [0023] The method may further include, in aspects, after the
removing step, adhering the
17 face mask with the perimeter portion of the adhesive layer adhered
thereto to a wearer's face via
18 the pressure-sensitive adhesive exposed on the upper surface of the
adhesive layer.
19 [0024] In aspects, removing the perimeter portion of the top
release liner may include
cracking and peeling the top release liner along a cut line that extends
across a width of the
21 perimeter portion of the top release liner.
CPST Doc: 299465.1 5
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0025] Peeling intact the two-layer perimetral strip portion
may include, in aspects,
2 peeling an edge of the two-layer perimetral strip portion along a peel
portion of the bottom
3 release liner that extends beyond a perimeter of the adhesive layer.
4 [0026] In further aspects, the two-layer perimetral strip
portion may be peeled away
along the perimeter cut formed through both the adhesive layer and the top
release liner, leaving
6 thereby separating the two-layer perimetral strip portion from the
central portion of each of the
7 adhesive layer and the top release liner and from the bottom release
liner.
8 [0027] The present disclosure is also directed to a method for
forming a face mask with a
9 perimeter seal using an embodiment of the perimeter seal device,
including exposing the
pressure-sensitive adhesive on the upper surface of the perimeter portion of
the adhesive layer,
11 and removing the perimeter portion of the top release liner; adhering,
by pressing, after the
12 exposing step, the perimeter seal device onto a periphery of the face
mask via the pressure-
13 sensitive adhesive exposed on the upper surface of the perimeter portion
of the adhesive layer;
14 and peeling away the bottom release liner to expose the pressure-
sensitive adhesive on the lower
surface of the adhesive layer. The perimeter portion of the adhesive layer
forms the perimeter
16 seal for the face mask.
17 [0028] In aspects, the peeling off and removing the perimeter
portion of the top release
18 liner may include peeling away the perimeter portion along the perimeter
cut through the top
19 release liner, leaving the central portion of the top release liner
intact.
[0029] In aspect, the method further includes removing, after the peeling
step, the central
21 portion of both the adhesive layer and the top release liner, the
perimeter portion of the adhesive
22 layer remaining on the mask to provide the perimeter seal.
CPST Doc: 299465.1 6
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0030] In further aspects, after the removing step, the method
includes adhering the face
2 mask with the perimeter portion of the adhesive layer adhered thereto to
a wearer's face via the
3 pressure-sensitive adhesive exposed on the lower surface of the perimeter
portion of the adhesive
4 layer.
[0031] In aspects, the peeling off and removing the perimeter portion of
the top release
6 liner includes cracking and peeling the top release liner along a cut
line that extends across a
7 width of the perimeter portion of the top release liner.
8 [0032] In some aspects, peeling away the bottom release liner
may include peeling an
9 edge of the bottom release liner along a peel portion that extends beyond
a perimeter of the
adhesive layer.
11 [0033] In addition to the above aspects of the present
disclosure, additional aspects,
12 objects, features and advantages will be apparent from the embodiments
presented in the
13 following description and in connection with the accompanying drawings.
14 BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The drawings constitute a part of this disclosure and include
examples, which
16 may be implemented in various forms. It is to be understood that in some
instances, various
17 aspects of the disclosure may be shown exaggerated or enlarged to
facilitate understanding. The
18 teaching of the disclosure can be readily understood by considering the
detailed description in
19 conjunction with the accompanying drawings, which are briefly described
below.
[0035] FIG. 1 is a pictorial view of a rear, user-facing side of a prior
art face mask with
21 no seal.
22 [0036] FIG. 2A is an exploded view of an embodiment of a
perimeter seal device of the
23 present disclosure for providing a face mask with a perimeter seal.
CPST Doc: 299465.1 7
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0037] FIG. 2B is a side view representation of the adhesive
layer, also referred to herein
2 as the "middle adhesive layer," of FIG. 2A.
3 [0038] FIG. 3 is a top view of an embodiment of a top release
liner forming a top layer of
4 a perimeter seal device of the present disclosure.
[0039] FIG. 4 is atop view of an embodiment of a perimeter seal device of
the present
6 disclosure having the three-layered structure of FIG. 2A, the top release
liner of FIG. 3, and a
7 central portion of the adhesive layer also having rounded corners, prior
to assembly on a mask.
8 [0040] FIG. 5 is a pictorial representation of the perimeter
seal device of FIG. 4 with an
9 edge of a perimeter portion of the top release liner lifted up for
peeling and removal, revealing a
perimeter portion of an adhesive layer below.
11 [0041] FIG. 6 is a pictorial representation of FIG. 5 with the
perimeter portion of the top
12 release liner completely removed, revealing a mask-facing side of the
perimeter portion of the
13 adhesive layer.
14 [0042] FIG. 7 is a view from a bottom surface of a bottom
release liner of remaining
portions of the perimeter seal device of FIG. 6, after removing the perimeter
portion of the top
16 release liner, with the perimeter portion of the adhesive layer shown in
FIG. 6 adhered to the
17 user-facing side of the prior art face mask of FIG. 1.
18 [0043] FIG. 8A is a view of the user-facing side of the face
mask of FIG. 1 showing the
19 perimeter portion of the adhesive layer of FIG. 6 remaining on the face
mask along with a central
portion of both the top release liner and adhesive layer of the perimeter seal
device of FIGS. 4-7
21 after removal of the bottom release liner.
CPST Doc: 299465.1 8
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0044] FIG. 8B is a view of the user-facing side of the face
mask of FIG. 8A, with the
2 central portion of the perimeter seal device of FIG. 8A removed, showing
the perimeter seal for
3 adhering the face mask to a user for use.
4 [0045] FIG. 9 is an exploded view of another embodiment of a
perimeter seal device of
the present disclosure for providing a face mask with a perimeter seal.
6 [0046] FIG. 10 is a top view of the perimeter seal device of
FIG. 9 prior to assembly to a
7 face mask.
8 [0047] FIG. 11A is a pictorial representation of both a
perimeter portion of the top
9 release liner together with a perimeter portion of a middle adhesive
layer, referred to as a two-
layer perimetral strip portion, being peeled off of a bottom release liner,
revealing a portion of a
11 lower surface of the middle adhesive layer.
12 [0048] FIG. 11B is a pictorial representation of the process of
removing the two-layer
13 perimetral strip portion of FIG. 11A intact from the bottom release
liner, revealing more of the
14 lower surface of the middle adhesive layer being pulled off of the
bottom release liner.
[0049] FIG. 12A is a view of a mask-facing side of the two-layer perimetral
strip portion
16 after removal as shown in FIG. 11B showing the lower surface adhesive
exposed for adhering to
17 a face mask.
18 [0050] FIG. 12B is a view of a top release-liner side of the
two-layer perimetral strip
19 portion after removal from the bottom release liner as shown in FIG.
11B.
[0051] FIG. 12C is an exploded view of the two-layer perimetral strip
portion of FIGS.
21 12A and 12B, after removal from the bottom release liner as shown in
FIG. 11B..
CPST Doc: 299465.1 9
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0052] FIG. 13A is a view of the user-facing side of the face
mask of FIG. 1, with the
2 mask-facing side of the two-layer perimetral strip portion shown in FIG.
12A adhered to the
3 perimeter of the face mask.
4 [0053] FIG. 13B is a view of FIG. 13A with an edge of a
perimeter portion of the top
release liner lifted up for peeling and removal of the perimeter portion.
6 [0054] FIG. 13C is a view of FIG. 13B with the perimeter
portion of the top release liner
7 completely removed, exposing an upper surface of the perimeter portion of
the middle adhesive
8 layer which forms a user-facing adhesive side for adhering the perimeter
seal to a user.
9 [0055] FIG. 14A is a top view of another embodiment of a
perimeter seal device in
accordance with the present disclosure.
11 [0056] FIG. 14B is an exploded view of the embodiment of the
perimeter seal device of
12 FIG. 14A, prior to assembly to a face mask.
13 [0057] FIG. 15 is a flow diagram representation of an
embodiment of a method for
14 converting a non-sealed face mask to a face mask with a perimeter seal,
using any of the
embodiments of a face mask formed in accordance with the present disclosure.
16 [0058] FIG. 16 is a flow diagram representation of another
embodiment of a method for
17 converting a non-sealed face mask to a face mask with a perimeter seal,
using any of the
18 embodiments of a face mask formed in accordance with the present
disclosure.
19 [0059] The various aspects of the present disclosure mentioned
above are described in
further detail with reference to the aforementioned figures and the following
detailed description
21 of exemplary embodiments.
CPST Doc: 299465.1 10
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 DETAILED DESCRIPTION
2 [0060] Particular illustrative embodiments of the present
disclosure are described
3 hereinbelow with reference to the accompanying drawings. The disclosed
embodiments are
4 merely examples of the invention, which may be embodied in various forms.
It should be
apparent to those skilled in the art that the embodiments described are
illustrative only and not
6 limiting, having been presented by way of example only. All features
disclosed in this
7 description may be replaced by alternative features serving the same or
similar purpose, unless
8 expressly stated otherwise. Therefore, numerous other modifications
thereof are contemplated as
9 falling within the scope of the present disclosure of a perimeter seal
for a face mask as defined
herein and equivalents thereto. Well-known functions or constructions and
repetitive matter are
11 not described in detail to avoid obscuring the present disclosure in
unnecessary or redundant
12 detail. Therefore, specific structural and functional details disclosed
herein are not to be
13 interpreted as limiting. In this description, as well as in the
drawings, like-referenced numbers
14 represent elements which may perform the same, similar, or equivalent
functions.
[0061] Throughout the description, where items are described as having,
including, or
16 comprising one or more specific components or features, or where methods
are described as
17 having, including, or comprising one or more specific steps, it is
contemplated that, additionally,
18 there are items of the present disclosure that consist essentially of,
or consist of, the one or more
19 recited components or features, and that there are methods according to
the present disclosure
that consist essentially of, or consist of, the one or more recited processing
steps.
21 [0062] The present disclosure is directed to a method and
device for providing a
22 perimeter seal for a face mask and for quickly converting a non-sealed
face mask to a sealed face
CPST Doc: 299465.1 11
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 mask for enhanced protection of the wearer from biological aerosols. The
present disclosure is
2 also directed to a method for manufacturing the perimeter seal device of
the disclosure.
3 [0063] FIG. 1 is a pictorial view of a rear, or user-facing
side of a typical prior art face
4 mask 12 manufactured with no seal. The face mask 12 includes an air-
filtering portion 14, and
may include ear loops 16 attached to a periphery 18 of the face mask 12 for
positioning and
6 retaining the air-filtering portion 14 over a mouth and nose of a wearer.
The face mask 12
7 shown in FIG. 1 is typically referred to as an "ear loop mask." The air-
filtering portion 14 may
8 also include a plurality of pleats 22 that allow vertical expansion of
the air-filtering portion 14
9 upon donning of the face mask 12 to cover a nose and mouth of a wearer
and, preferably, to
extend beyond the chin in a vertical direction. The peripheral edges of the
air-filtering portion
11 14, which is typically a multi-layered construction, are typically
bonded, adhered, stitched, or
12 otherwise secured together, but no seal is provided for sealing to a
wearer's face. Most prior art
13 face masks also include a bendable nose strip 20 either attached to an
outside surface of the face
14 mask 12 or sewed into an internal pocket for better conformation of the
face mask 12 to contours
of the face around the nose.
16 [0064] FIG. 2A is an exploded view of an embodiment of a
perimeter seal device
17 configured for sealing the face mask 12 of FIG. 1 directly to a wearer's
face. In embodiments,
18 the perimeter seal device can be configured to seal any prior art face
mask, of any shape. In
19 particular, it should be understood that while most of the embodiments
of the perimeter seal
device shown and described herein are shaped for sealing the rectangularly
shaped prior art mask
21 represented by FIG. 1, these embodiments are exemplary only and not
limited thereto. It will be
22 understood by one of skill in the art that embodiments of the perimeter
seal device may be
23 constructed as described herein in any appropriate shape to match a
shape of a perimeter of any
CPST Doc: 299465.1 12
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 manufactured face mask for applying a seal thereto, including round or
oval, with or without
2 pleats, and so on, and are not limited to shapes or types of masks
represented herein.
3 [0065] Referring to FIG. 2A as well as to FIG. 9, embodiments
of the perimeter seal
4 device for applying to a face mask include a three-layered structure 25
with the three layers
sandwiched together in the manufacturing process. An exploded view of the
three-layered
6 structure 25 is shown in each of FIGS. 2A and 9. The three-layered
structure 25 includes a top
7 release liner 32 forming a top layer, and an adhesive layer 34, also
referred to herein as a "middle
8 adhesive layer," forming a middle layer. Referring also to FIG. 2B, the
middle adhesive layer 34
9 includes a carrier 33, or substrate, with a pressure-sensitive adhesive
35 (also referred to herein
as "PSA") layered on each of an upper surface 37 and a lower surface 39 of the
substrate 33 of
11 the adhesive layer 34, and, in embodiments, forms a two-sided releasable
pressure-sensitive
12 adhesive layer. The three-layered structure 25 also includes a bottom
release liner 36 forming a
13 bottom layer, which is, in embodiments, one continuous bottom release
liner. As further
14 described herein, a peel portion 60 of the bottom release liner 36
preferably extends beyond a
perimeter of the adhesive layer 34, and in embodiments, also beyond a
perimeter of the top
16 release liner 32, which may be of the same outer dimensions as the
adhesive layer 34, to provide
17 an edge for easily peeling away the bottom release liner 36.
18 [0066] In embodiments, each of the top release liner 32 and the
bottom release liner 36 is
19 about 3.2 mils (millionths of an inch) thick. In further embodiments,
each of the top release liner
32 and the bottom release liner 36 are silicone coated liners, with the
silicone-coated side facing
21 the adhesive layer 34.
22 [0067] Referring to FIG. 2B, for example, the middle adhesive
layer 34 may be formed
23 of a carrier 33 coated on both sides 37, 39 with a layer of the pressure-
sensitive adhesive 35.
CPST Doc: 299465.1 13
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 The pressure-sensitive adhesive (PSA) 35 may include any suitable PSA for
adhering to the skin.
2 In embodiments, the PSA may include an acrylic adhesive of medical grade.
In still other
3 embodiments, the PSA may include a silicone or non-latex composition.
4 [0068] In embodiments, each of the layers of pressure-sensitive
adhesive 35 are about 1.8
mil ("mil" refers to millionths of an inch) thick, and the carrier may be
about 3 mils thick.
6 [0069] The carrier may be any suitable carrier, and in
embodiments, may be a thin plastic
7 film, and in further embodiments, a stretchable plastic film. In still
further embodiments, the
8 carrier is a polyethylene, in embodiments, a low density polyethylene
(LDPE).
9 [0070] In embodiments, the carrier may include a polyethylene,
polypropylene,
polyester, or a polyurethane.
11 [0071] In additional embodiments, the carrier may be a foil,
cloth, paper, or tissue
12 material.
13 [0072] Various materials may be used to form the top release
liner 32 and the bottom
14 release liner 36. In embodiments, the release liners 32, 36, include a
base or substrate 41 (see
FIG. 12C), which may be formed, in embodiments, of paper, or of a plastic
film. Suitable
16 materials for the substrate may include, but are not limited to, paper
materials such as Super
17 Calendered Kraft ("SCK"), glassine, various types of coated paper,
machine finished Kraft
18 paper, and machine glazed paper; and plastic films such as terephthalate
("PET") typically
19 extruded as a biaxially oriented PET film, or "BO-PET", polypropylene
("PP") which may be
extruded as a biaxially oriented polypropylene ("BOPP") film, polyolefin, and
polyethylene
21 ("PET"). The substrate or "liner" is coated on at least one side with a
release agent to form a
22 release side from which an adhesive surface, i.e., the upper surface 37
or lower surface 39
23 covered with the PSA 35, can be separated.
CPST Doc: 299465.1 14
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 [0073] In the three-layered structure 25 of the embodiments of
the present disclosure,
2 referring to FIG. 2A as well as 12C, for example, at least a lower
surface 74 of the top release
3 liner 32 that contacts the upper surface 37 of the middle adhesive layer
34 is coated with a
4 release agent, such as silicone. Similarly, at least an upper surface 76
of the bottom release liner
36 that faces the lower surface 39 of the middle adhesive layer 34 is
preferably coated with a
6 release agent, such as silicone. In embodiments, the top release liner 32
of the device is silicone-
7 coated on the lower surface 74, and the bottom release liner 36 is
silicone-coated on upper
8 surface 76.
9 [0074] In other embodiments, the lower surface 74 and upper
surface 76 are coated with
any suitable release agent.
11 [0075] In embodiments, referring still, for example, to FIG.
2A, either an upper surface
12 78 or the bottom surface 72 of the three-layered structure 25 may be
printed with a two-
13 dimensional bar code 79, e.g., a quick response "QR" code, which when
scanned, opens up a
14 website or application containing directions that a user can quickly
access, with a video and
instructions for applying the perimeter seal device 30, for example, to the
face mask 12 to
16 provide a perimeter seal 80 (see FIG. 8B) in accordance, for example,
with methods described
17 herein.
18 [0076] As further described herein, the three-layered structure
25 of the perimeter seal
19 device is configured to transfer and adhere a perimeter portion 38 of
the middle adhesive layer
34 to the perimeter 18 of the user-facing side 10 of a face mask, face mask
12, for example. It
21 should be noted that "perimeter portion" as used herein refers to a
perimetral strip configured to
22 align with the peripheral shape and peripheral dimensions of a face
mask, so that an adhesive
23 seal of a width defined by the width of the perimeter portion or strip,
is formed all around the
CPST Doc: 299465.1 15
Date Recue/Date Received 2020-10-19
CA Application
CPST Ref: 11271/00007
1 periphery of the mask. A portion of the face mask 12 corresponding to the
perimeter portion 38
2 adhered thereto is then adhered directly to a user's face via the
pressure-sensitive adhesive 35 on
3 an exposed surface of the perimeter portion 38 of the adhesive layer 34,
as further described
4 herein. As further described herein, the exposed surface for adhering to
a user's face may be
either the upper surface 37 or the lower surface 39 of the adhesive layer 34,
depending on the
6 method used to apply the perimeter portion 38 of the adhesive layer 34 to
the face mask.
7 [0077] The embodiments shown in reference to FIG. 2A, as well
as FIG. 9, are
8 configured for use with a rectangular face mask, such as the ear loop
mask 12 of FIG. 1,
9 typically having dimensions of approximately 3.5" x 7". Accordingly, the
outer dimensions of
the top release liner 32 and middle adhesive layer 34, in embodiments, are
about 3.5" x 7". Each
11 of the top release liner 32 and adhesive layer 34 may be configured for
any shape and size of
12 face mask, and preferably have substantially the same perimeter
dimensions as the face mask
13 onto which it is assembled. Each of the top release liner 32 and middle
adhesive layer 34
14 preferably has a perimeter cut 40 to define a perimeter portion 42 in
the top release liner 32 and
the perimeter portion 38 in the adhesive layer 34. In embodiments, the
perimeter cut 40 may be
16 of the same shape as the face mask itself, for example, rectangular, as
shown in FIG. 2A, or, for
17 example, a perimeter cut 140 may be oval-shaped, for an embodiment 130
of a perimeter seal
18 device configured for an oval-shaped or round face mask, as shown in
FIGS. 14A-14B.
19 [0078] In embodiments, referring to FIG. 2A, a central portion
45 of the top release liner
32 and adhesive layer 34 formed by the perimeter cut 40 is preferably centered
to the edges of
21 each of the top release liner 32 and middle adhesive layer 34 of the
perimeter seal device 30.
22 [0079] In embodiments, as shown in FIGS. 3 and 9, for example,
the perimeter cut 40'
23 may be of a slightly different shape than of the face mask itself, for
example, having a
CPST Doc: 299465.1 16
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CA Application
CPST Ref: 11271/00007
1 rectangular shape, but with rounded corners. For example, the perimeter
cut 40' through each of
2 the top release liner 32 and the middle adhesive layer 34, which is
preferably centered to the
3 edges of the top release liner 32 and middle adhesive layer 34, may be in
a rectangular shape
4 with rounded corners, which may be, in embodiments, of about 1/8" radius,
or in other
embodiments, 14" radius, or in additional embodiments, about 1/2" radius
rounded corners.
6 [0080] In still additional embodiments, the outer dimensions of
the top release liner 32
7 and middle adhesive layer 34 are about 3.5" x 7", being configured for a
rectangular face mask
8 of similar outer dimensions. The perimeter cut 40' through each of the
top release liner 32 and
9 the middle adhesive layer 34 is rectangular shaped and centrally located
.5" inward from the
edges of the outer dimensions, to form central portions 45. This forms an
approximate .5" wide
11 perimeter portion 42 in the form of a rectangular-shaped perimetral
strip on the periphery of the
12 top release liner 32 and middle adhesive layer 34, with, in embodiments,
rounded corners of
13 .. about 1/2" radius.
14 [0081] The perimeter cuts 40 shown in FIG. 2A, as well as the
perimeter cuts 40' shown
in FIG. 9, and the perimeter cuts 140 of the embodiment of FIG. 14, are
preferably formed
16 during manufacture after the three-layered structure is sandwiched
together, by a kiss-cut made
17 simultaneously through each of the top release liner 32 and middle
adhesive layer 34.
18 [0082] In embodiments, the perimeter cut 40, 40', 140, may be
positioned 1/2" in from the
19 outer edges or perimeter of each of the top release liner 32 and the
middle adhesive layer 34,
forming a perimeter portion 42 in the top release liner 32 and a perimeter
portion 38 in the
21 middle adhesive layer 34, so that in embodiments, the perimeter portions
38, 42, are
22 approximately 1/2" wide. The perimeter cut 40, 40', 140 also defines a
central portion 45 which,
23 in embodiments, is centered in the middle of each of the top release
liner 32 and the middle
CPST Doc: 299465.1 17
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1 adhesive layer 34. Accordingly, once the face mask 12 is assembled with,
for example, the
2 perimeter face seal device 30 of FIG. 2A or the embodiment 30' of FIG. 9,
as further described
3 herein, a 1/2" wide perimetral strip of adhesive will result all around
the perimeter 18 of the user-
4 facing side 10 of the face mask 12 for adhering to a user's face.
[0083] The device 30' of FIG. 9 differs from the device 30 shown in FIG. 2A
in the
6 shape of the perimeter cuts 40', which form central portions of
rectangular-shape like those of
7 FIG. 2A, but with rounded corners. The device 30' of FIG. 9 also differs
in having the peel
8 portion 60, which is adhesive-free, also referred to herein as a "dry
peel portion," in the bottom
9 release liner 36 along only one edge, in the example shown, along the
left edge 56, rather than
along both the left 56 and the right edge 58 of the top release liner 32 and
adhesive layer 36 of
11 the device 30, as shown in FIG. 2A. Similarly, the difference in the
device 130 of FIGS. 14A-
12 14B is driven by the particular shape of the oval or round-type face
masks for which it is
13 configured, so that, in this embodiment, the bottom release liner 36, in
embodiments, particularly
14 for round or oval face masks, is of the same shape as, but wider than,
and centered to, the top
release liner 32 and middle adhesive layer 34.
16 [0084] In embodiments, the bottom release liner 36 is sized to
provide an approximate
17 3/4" to 1/2" peel portion 60 all around the edges of the top release
liner 32 and middle adhesive
18 layer 34.
19 [0085] Referring to FIGS. 2A, 3-5, 9-11B, 12B-13B, and 14A-14B,
the top release liner
32 also includes a cut 50 (referred to herein as a "crack-and-peel cut"),
which provides a crack-
21 and-peel edge 51 (FIGS. 5, 13B) for peeling. The cut 50 extends only
through the top release
22 liner 32, and only across the perimeter portion 42. The cut 50 extends
across a width of the
23 perimeter portion 42, i.e., from a perimetral edge 61 to the perimeter
cut 40 in the top release
CPST Doc: 299465.1 18
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CA Application
CPST Ref: 11271/00007
1 liner 42. In embodiments, the crack-and-peel cut 50 may be centered along
a wider side of the
2 top release liner 32, which may, in embodiments, correspond to the center
of a wider side 52 of
3 the perimeter seal device 30, as shown in FIG. 4, for example.
4 [0086] Like the perimeter cuts 40, the crack-and-peel cut 50 is
preferably formed during
manufacture after the three-layered structure is sandwiched together, by a
kiss-cut made only
6 through the top release liner 32 and not through the adhesive layer 34.
7 [0087] Referring to FIGS. 2A, 4, 5, 6 and 7, as well as to the
embodiments of FIGS. 9-
8 13B, and FIGS. 14A-14B, the bottom release liner 36 preferably extends
beyond a perimeter 61
9 (also referred to as a "perimetral edge 61") of each of the top release
liner 32 and middle
adhesive layer 34 of the perimeter seal device for easy removal during
assembly of the perimeter
11 seal device to a face mask. In embodiments, referring to FIG. 2A, as
well as to the embodiment
12 of FIGS. 14A-14B, the bottom release liner 36 may be centered to the top
release liner 32 and
13 middle adhesive layer 34 and extend beyond the widths of each of top 32
and middle layers 34.
14 [0088] In embodiments, referring to the device 130 of FIGS. 14A-
14B, the bottom
release liner 36 has a greater width along at least one of the axes of the
oval, and in the case of a
16 circular device, the bottom release liner 36 may have a greater diameter
than that of the top 32
17 and middle layers 34.
18 [0089] In embodiments, referring again to FIGS. 2A and 4, for
example, the bottom
19 release liner 36 may extend in width 54, e.g., along the wider side 52
of a rectangularly shaped
top release liner 32 and middle adhesive layer 34, beyond both the left 56 and
right edges 58 of
21 the top release liner 32 and middle adhesive layer 34. As best shown in
FIG. 6, this leaves a peel
22 portion 60 that extends beyond a perimeter 61, or perimetral edge 61, of
the middle adhesive
CPST Doc: 299465.1 19
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1 layer 34, and in embodiments, of the top release liner 32, along each
side 56, 58, of the perimeter
2 seal device 30.
3 [0090] In other embodiments, as shown in FIGS. 9-11B, the
bottom release liner 36
4 preferably extends beyond at least one edge, e.g., the left edge 56 of
each of the top 32 and
middle layers 34 of the perimeter seal device, leaving a dry peel portion 60
along, for example,
6 the left edge 56.
7 [0091] In embodiments, each dry peel portion 60 may be about
14" wide. In
8 embodiments, the dry peel portion 60 is between about 14" and 1/2" wide.
9 [0092] Various methods may be used to transfer and adhere the
perimeter portion 38 of
the adhesive layer 34 of a perimeter face mask seal device of the present
disclosure to a face
11 mask for forming a perimeter face mask seal. FIGS. 5-8B represent an
embodiment of a method
12 for converting a non-sealed face mask to a face mask with a perimeter
seal, or for providing a
13 face mask with a perimeter seal, with reference to the embodiment of the
device 30 represented
14 by FIGS. 2A-4, and may also be applied to the three-layered structure 25
of device 30' shown in
FIGS. 9 and 10, and of device 130 of FIGS. 14A-14B.
16 [0093] With reference to FIGS. 4 and 5, which are top views of
an embodiment of the
17 assembled three-layered structure 25 of FIGS. 2A and 3, embodiments of a
method 100, as
18 disclosed in FIG. 15, for converting the face mask 12 to a face mask 90
with a perimeter seal 80
19 as shown in FIG. 8B includes providing, at 102, the three-layered
structure 25 of an embodiment
of the perimeter seal for a face mask in accordance with the present
disclosure, and exposing, at
21 104, the pressure-sensitive adhesive 35 on the upper surface 37 of the
perimeter portion 38 of the
22 middle adhesive layer 34, which includes, in embodiments, cracking and
peeling back, at 106, an
23 edge portion 70 of the perimeter portion 42 of the top release liner 32
along the crack-and-peel
CPST Doc: 299465.1 20
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CA Application
CPST Ref: 11271/00007
1 cut 50, and continuing peeling until the perimeter portion 42 of the top
release liner 32, at 108, is
2 completely removed, as shown in FIG. 6. This exposes the adhesive 35 on
the upper surface 37
3 of the perimeter portion 38 of the middle adhesive layer 34. In this
embodiment of a method for
4 converting a non-sealed face mask to a face mask with a perimeter seal,
the upper surface 37 of
the perimeter portion 38 is a mask-facing side of the perimeter seal device
30.
6 [0094] As further described herein, after exposing the upper
surface 37 of the perimeter
7 portion 38 of the adhesive layer 34, at 104, as shown in FIG. 6, the
perimeter portion 38, with the
8 remaining central portions 45 and bottom release liner 36 of the three-
layered structure 25 still
9 attached thereto, is adhered, at 110, to the face mask. In particular,
after aligning the perimeter
portion 38 to the perimeter 18 of the face mask, with the exposed PSA 35
facing the user-facing
11 side of the face mask 12, the adhering step, at 110, includes pressing,
or applying pressure on the
12 bottom release liner 36 side of the device 30 to adhere the perimeter
portion 38 around the
13 perimeter 18 of the user-facing side 10 of the face mask 12, as shown,
for example, in FIG. 7. In
14 this view, in which the upper surface 37 of the perimeter portion 38 of
the adhesive layer 34 is
adhered to the user-facing side 10 of the face mask 12, only the bottom
surface 72 (see also
16 FIGS. 2A, 9, 14B) of the bottom release liner 36 can be seen. It should
be clear that the exposed
17 adhesive 35 in the upper surface 37 of the perimeter portion 38 is
adhered to the perimeter 18 of
18 the face mask 12, so that the bottom release liner 36 portion(s) 60 that
extend beyond the
19 adhesive layer 34 likewise extend beyond the edges 18 of the mask 12 in
this assembly step.
[0095] Once the device 30, for example, is pressed onto the user-facing
side 10 of the
21 face mask 12, adhering, at 110, the exposed adhesive 35 in the upper
surface 37 of the middle
22 adhesive layer 34 to the perimeter 18 of the face mask 12 as shown in
FIG. 7, the bottom release
23 liner 36, which is preferably one continuous sheet, is peeled away, at
112, and discarded.
CPST Doc: 299465.1 21
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1 Referring to FIG. 8A, this exposes the adhesive 35 on the lower surface
39 of the middle
2 adhesive layer 34, including along the perimeter portion 38, to form a
user-facing side of the
3 perimeter portion 38 for adhering to a wearer's face. As shown in FIG.
8A, the adhesive 35 on
4 the lower surface 39 of the central portion 45 of the middle adhesive
layer 34 is also exposed
after removing the bottom release liner, with the central portion 45 of the
middle adhesive layer
6 34 and the central portion 45 of the top release liner 32 still remaining
intact.
7 [0096] In a final step of this embodiment of a method for
converting the face mask 12 to
8 a face mask with a perimeter seal, the remaining central portion 45 of
each of the top release
9 liner 32 and the middle adhesive layer 34 attached thereto, at 114, are
removed, preferably in one
step, leaving only the perimeter portion 38 of the middle adhesive layer 34
adhered to the face
11 mask 12 via the pressure sensitive adhesive 35 on the upper surface 37
of the perimeter portion
12 38. The adhesive 35, now exposed, on the lower surface 39 of the
perimeter portion 38, see FIG.
13 8B, is the user-facing side of the perimeter portion 38 of the adhesive
layer 34 in this
14 embodiment, and provides a perimeter seal 80 on the face mask 12 for
adhering to a user's face.
[0097] After applying the method to form a face mask 90 with a perimeter
seal from non-
16 sealed face mask 12, the perimeter 18 of face mask 12 is adhered via the
perimeter adhesive seal
17 80 directly to a user's face to seal the perimeter 18 of the face mask
12 tight to the wearer's face.
18 [0098] For simplicity, the method 100 is described herein with
reference to certain
19 embodiments of a face mask perimeter seal device; however, it should be
appreciated that any of
the embodiments of methods of the present disclosure can be applied using any
embodiment of a
21 perimeter seal device including the three-layered structure as shown and
described herein, and
22 equivalents thereof, including those shown herein.
CPST Doc: 299465.1 22
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1 [0099] Referring to FIG. 16, another embodiment of a method for
converting a non-
2 sealed face mask to a face mask with a perimeter seal, using a face mask
seal device, is described
3 with reference to the embodiment of the device 30' represented by FIGS. 9
and 10.
4 [00100] It will be appreciated that in the method represented
by FIG. 15, described herein
in reference to FIGS. 2A-8B, the upper surface 37 of the perimeter portion 38
of the middle
6 adhesive layer 34 forms the face mask-facing side that is adhered to the
face mask and, referring
7 to FIG. 8B, the lower surface 39 of the perimeter portion 38 of the
middle adhesive layer 34
8 forms the perimeter seal 80 for adhering the face mask to a user's face.
In the method
9 represented by FIG. 16, described herein below with reference to FIGS. 10-
13C, the lower
surface 39 of the perimeter portion 38 of the middle adhesive layer 34 forms
the mask-facing
11 side that is adhered to the face mask and, referring to FIG. 13C, the
upper surface 37 of the
12 perimeter portion 38 of the middle adhesive layer 34 forms the perimeter
seal 80' for adhering
13 the face mask with the perimeter seal 90' of FIG. 13C to a user's face.
Either method can be
14 applied to any embodiment of a face mask seal device described herein
and equivalents thereof.
[00101] Referring to FIG. 16, an embodiment 120 of another method for
converting a non-
16 sealed face mask to a face mask with a perimeter seal, with reference to
FIGS. 10 ¨ 12C,
17 includes removing intact, at 122, a two-layer perimetral strip portion
62, which includes the
18 perimeter portion 42 only of the top release liner 32 together with the
perimeter portion 38 only
19 of the middle adhesive layer 34, from the bottom release liner 36, and
disposing of the central
portions 45 together with the bottom release liner 36. Referring to FIG. 10
and 11A, removal of
21 the two-layer perimetral strip portion 62 is facilitated by the dry peel
portion 60 of the release
22 liner 36, the two-layer perimetral strip portion 62 being easier to lift
at a corner of the two-layer
23 perimetral strip portion 62 adjacent the dry peel portion 60, as shown
in FIG. 11A. FIG. 11B
CPST Doc: 299465.1 23
Date Recue/Date Received 2020-10-19
CA Application
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1 illustrates the two-layer perimetral strip portion 62 being separated
from the central portions 45
2 of both the top release liner 32 and the middle adhesive layer 34 and
peeled off of the bottom
3 release liner 36. A user may push down on the central portion 45 while
lifting the two-layer
4 perimetral strip portion 62 to easily separate it from the central
portion 45. As previously
described, in embodiments, two peel portions 60 are provided along two edges
56, 58 of the
6 adhesive layer 34, the adhesive layer 34 and the top release liner 32 in
embodiments being
7 centered on the bottom release liner 36 to form the two peel portions 60
(see FIG. 6, e.g.).
8 [00102] As best shown in FIG. 12C, referring also to FIG. 9, as
a result of peeling off the
9 two-layer perimetral strip portion 62, the pressure-sensitive adhesive 35
on the lower surface 39
of the perimeter portion 38 of the middle adhesive layer 34 is exposed, at
124, on a bottom
11 surface 64 of the separated two-layer perimetral strip portion 62, which
is shown in FIG. 12A, to
12 form the mask-facing side that is adhered to a face mask, the bottom
surface 64 forming the
13 mask-facing side in this embodiment of a method for forming a perimeter
seal for a face mask.
14 The perimeter portion 42 of the top release liner 32 forms a top surface
66 of the two-layer
perimetral strip portion 62, as shown in FIG. 12B and 12C.
16 [00103] At 126, referring to FIG. 16, the two-layer perimetral
strip portion 62 is adhered
17 to the face mask 12, as shown in FIG. 13A, via the pressure-sensitive
adhesive 35 on the bottom
18 surface 64 of the two-layer perimetral strip portion 62, by aligning the
two-layer perimetral strip
19 portion 62 to the perimeter 18 of the face mask, with the bottom surface
64 contacting the face
mask 12, and applying pressure to the top surface 66.
21 [00104] At 130, referring to FIGS. 16 and 13B, the perimeter
portion 42 is then removed
22 to expose PSA 35 from the upper surface 37 of the perimeter portion 38
of the middle adhesive
23 layer 34. As shown in FIG. 13B, removing the perimeter portion 42
includes, in embodiments,
CPST Doc: 299465.1 24
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1 cracking and peeling back, at 128, edge portion 70 of the perimeter
portion 42 of the top release
2 liner 32 along the crack-and-peel cut 50, and continuing peeling until
the perimeter portion 42 of
3 the top release liner 32, at 128, is completely removed, as shown in FIG.
13C.
4 [00105] Referring to FIG. 13C, the upper surface 37 of the
perimeter portion 38 of the
middle adhesive layer 34 forms the user-facing side of the perimeter seal 80'
for adhering the
6 face mask 90' of FIG. 13C to a user's face. The face mask with perimeter
seal 80 or 80' adhered
7 thereto, as shown in FIG. 8B or FIG. 13C, is then adhered to the
perimeter of a wearer's face.
8 [00106] The perimeter seal 80, 80' of the present disclosure
closes air gaps between the
9 face mask and the face in use, blocking, or at least minimizing,
unfiltered air from leaking in
around the perimeter of the face mask. The result is that air flow is directed
through the front of
11 the mask, and is thus filtered through filtering media 14, before
reaching the wearer. In a recent
12 test, the inventors demonstrated that half the wearers of a Level 3 ear
loop mask with a perimeter
13 seal of the present disclosure passed the fit test required of an N95
respirator. Accordingly, the
14 perimeter seal device of the present disclosure provides a cost-
efficient, easy to apply, seal for
applying to the perimeter of a manufactured face mask, such as a surgical
mask, or ear-loop
16 mask, which improves the filtering efficiency of a commercial, otherwise
non-sealed face mask.
17 [00107] While the invention has been particularly shown and
described with reference to
18 specific embodiments, it should be apparent to those skilled in the art
that the foregoing is
19 illustrative only, not limiting, and presented by way of example only.
The disclosed
embodiments may be embodied in various forms and detail without departing from
the spirit and
21 scope of the disclosure. Therefore, specific structural and functional
details disclosed herein are
22 not to be interpreted as limiting. Numerous other embodiments may fall
within the scope of the
23 accompanying claims and equivalents thereto.
CPST Doc: 299465.1 25
Date Recue/Date Received 2020-10-19
