Note: Descriptions are shown in the official language in which they were submitted.
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RESPIRATOR MASK FOR LONG-TERM USE
PRIORITY CLAIM
[00011 This application claims priority to and the benefit as a non-
provisional
application of U.S. Provisional Patent Application No. 63/027,546, filed May
20, 2020, U.S.
Provisional Patent Application No. 63/123,759, filed December 10,2020, and
U.S. Provisional
Patent Application No. 63/171,885, filed April 7,2021, the entire contents of
which are hereby
incorporated by reference and relied upon.
[0002] This application also claims priority to U.S. Design Application No.
29/771,847, filed February 25, 2021, the entire contents of which is hereby
incorporated by
reference and relied upon.
TECHNICAL FIELD
[0003] The present disclosure relates generally to a respirator mask, and in
particular
to a reusable respirator mask with replaceable filters.
BACKGROUND
[0004] Generally, there are two main types of known filtering respirators. One
type is
a disposable respirator, which may be used by, for example, a construction
worker to mitigate
dust inhalation during a short-term sanding operation. The second type is a
reusable elastomeric
facepiece respirator. These reusable respirators tend to be worn by employees
whose
occupation regularly exposes them to hazardous materials on a continual basis,
such as a
chemical engineer in a manufacturing plant. Depending upon the application,
each type of
mask possesses advantages and disadvantages.
Disposable Respirator
[0005] A primary advantage of a disposable respirator (also referred to as a
"mask") is
its inherent sterility and simplicity. For instance, a wearer can quickly
deploy a new mask to
their face with minimum training to obtain a reasonable amount of
protection¨at least for a
short duration. This disposable nature of the mask means that wearers do not
need to be trained.
Additionally, processes and facilities do not need to be established for
sterilization,
maintenance, and safe storage of used masks.
[0006] However, disposable masks also possess a number of disadvantages. For
instance, disposable masks tend to fit poorly, especially over hard tissue,
such as the area
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around the bridge of a wearer's nose. This in turn causes the loss of an
airtight seal around the
wearer's face, which allows pathogens and other dangerous particles to bypass
filter media and
potentially enter the body through the nose or mouth. Published medical
research indicates
that the loss of an airtight seal can reduce respirator mask effectiveness by
up to 90%.
[0007] In addition to fitment issues around the bridge of the nose, disposable
masks
also tend to slide up and down on a wearer's face, especially when the wearer
talks. This
movement breaks the air seal and also often leads the wearer to use their hand
to adjust the
mask during or after a conversation
______________________________________________ an act which potentially
contaminates the surface of the
mask. Even trained medical personnel are not immune from this effect. For
example, a 2013
study of ten nurses wearing N95 masks found a mean of 14.6 touches to the mask
and 6.6
adjustments of the mask on the first day of use. See Physiologic and other
effects and
compliance with long-term respirator use among medical intensive care unit
nurses, Rebmann,
Terri et al., American Journal of Infection Control, Volume 41, Issue 12, 1218
- 1223.
[0008] Another issue with disposable masks is the relatively narrow outer edge
that
forms the airtight seal with the wearer's skin. Even in short periods of less
than an hour, these
edges tend to generate depressions in the skin of a wearer due to the
compression against the
face. This in turn causes discomfort for the wearer. Over time, wearers
respond to this
discomfort by lifting the mask, or at least the edge of the mask, to release
temporarily the
pressure at the affected area¨an action that breaks the air seal and risks
transferring viral
particles to the interior of the mask and wearer's nose, mouth, and eyes.
[0009] Disposable masks are often worn with the straps incorrectly placed. To
maximize effectiveness, the lower strap should extend from the mask to the
back of the neck
and be placed below the ear. The upper strap should travel from the mask to
the top rear area
of the head and be placed above the ear. However, many users leave both straps
down at the
neck for convenience or to relieve the pressure on their skin from the edge of
the mask. In
either case, the air seal is not effectively established and maintained if the
mask is not properly
secured.
[0010] A further disadvantage of disposable masks is flow rate and resistance
on
inhalation and exhalation. In this context, flow rate refers to the
communication of air through
single or multiple layers of filter media and is commonly measured in liters
per minute (L/min).
Resistance refers to the maximum pressure drop during this communication and
is usually
measured in pascals (Pa). Depending on the mask design as well as industry
and/or national
standards, one or both values may be different for inhalation versus
exhalation. For example,
the flow-rate minimum standard for N95 disposable masks is 85 L/min for both
inhalation and
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exhalation. The inhalation resistance standard is < 343 Pa and < 245 for
exhalation. See
NIOSH-42C FR84.
[0011] However, in real-world use, these standards for -breathability" often
leave users
feeling short of breath after a few minutes, even during sedentary behavior,
such as sitting and
reading. Naturally, this discomfort increases with the level of activity as
the body requires
more oxygen. In the aggregate, these varying levels of discomfort discourage
users from
wearing masks, or at least wearing them correctly, for prolonged periods of
time. Users, even
trained users, often react by engaging in non-compliant behavior, such as
lifting the mask to
take a few quick unrestricted breaths of air.
[0012] For similar reasons, disposable masks also tend to suffer from the
buildup of
excessive heat and humidity, even during moderate activity in mild climates.
Although heat
radiating from the wearer's face contributes to this problem, the largest
factor tends to be heat
and humidity introduced into the mask during exhalation. Aside from the
obvious discomfort,
the heat and humidity tend to cause the generation and pooling of sweat within
the mask, which
most users describe as extremely uncomfortable. To release the sweat and clear
the mask, users
will use their (possibly contaminated) hands to lift the mask away from their
face and allow
the sweat to roll down their face and neck¨a process that, again, breaks the
air seal and risks
contaminating surfaces. Even when the wearer does not clear the mask, the
moisture from
exhalation tends to build up in and reduce the flow rate of the filter media,
which reduces both
its effectiveness and lifespan.
[0013] To help address exhalation flow rate and the buildup of heat and
humidity within
the mask, some mask designs include an exhalation value. This type of valve
provides a low-
pressure route for unfiltered air from the wearer's lungs to communicate
outside the mask.
Upon exhalation, air from the wearer's lung temporarily increases pressure
within the interior
of the mask. The air then follows the path of least resistance via the
exhalation valve to the
lower pressure environment outside the mask.
[0014] For most wearers, inclusion of an exhalation valve provides for less
restrictive
and cooler breathing with less moisture build up inside the faceplate.
However, the use of an
exhalation valve only helps with mitigation. The exhalation valve does not
solve the moisture
buildup problem since moisture from the exhaled air still attaches to the
interior surface of the
filter media, resulting in reduced effectiveness and lifespan.
[0015] Inclusion of an unfiltered exhalation valve bears another more
significant
drawback with regard to pathogenic protection. While an exhalation valve
protects a wearer
from a contaminated environment, it does not protect the environment (and
people in that
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environment) from a contaminated wearer. Specifically, the valve acts like a
chimney that
communicates aerosolized particulates from inside the mask into the outside
environment. For
this reason, the CDC states on its website that disposable masks -with
exhalation valves should
not be used in situations where a sterile field must be maintained (e.g.,
during an invasive
procedure in an operating or procedure room) because the exhalation valve
allows unfiltered
exhaled air to escape into the sterile field." See
https://www.cdc.gov/coronavirus/2019-
ncov/hcp/respirator-use-faq.html.
[0016] Disposable respirators also suffer from a relatively short shelf life
before
expiration. Respirator manufacturer 3M explains on its website: "The longer a
respirator has
been in storage, the less likely it is to perform at its full potential. Over
time, components such
as the strap and nosefoam may degrade, which can affect the quality of the fit
and seal."
[0017] The list of disadvantages described above for disposable respirators is
representative and not exhaustive. However, most if not all of these issues
become more acute
in occupations that involve the long-term, continual use of a mask over a full
work shift, like a
hospital worker, and even more so during non-stop continual use over months,
such as by a
sailor deployed on a warship.
Reusable Elastomeric Facepiece Respirator
[0018] The second type of respirator is a reusable elastomeric facepiece
respirator
("reusable respirator"). Although different manufacturers utilize slightly
different terminology
in their description, these types of products generally combine an elastomeric
facepiece with
robust straps and replaceable filter media, usually in the form of a snap- or
screw-on cartridge.
See, for example, the line of 3M products at
https://www.3m.com/3M/en_US/company-us/all-
3m-
products/?N=5002385+8709322+8711017+8711405+8720539+8720550+3294857497&ft=r3
[0019] The main benefit of a reusable respirator is that it provides a much
higher degree
of comfort against the skin of the wearer and, if worn and used properly, also
provides a
qualitatively better air seal. Some reusable respirators include both an
inhalation valve and an
exhalation valve for another advantage. In these products, the inhalation
valve closes on
exhalation, which redirects exhaled air (with its heat and humidity) away from
the filter media
and towards the exhalation valve. The result is a cooler mask that provides
easier breathability
for wearers.
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[0020] However, reusable respirators also have disadvantages. First, both the
respirators and the filter media (cartridges) are far more expensive than
disposable respirators.
For instance, the cost of a mid-range reusable respirator is up to 100X that
of a disposable
respirator. The replaceable filters utilized by these masks are also expensive
and can cost up
to 25X the cost of a disposable respirator.
[0021] A second disadvantage is that reusable respirators require
significantly more
training of the wearer for its protections to be effective. Contamination is a
particular risk when
doffing a reusable respirator. Wearers also need to learn how to assemble and
don according
to procedure, how to adjust the straps for fit, how to exchange the filter
cartridges, etc.
Additionally, complex and multiple parts translate into extended times to don
and doff This
issue may reduce wearer availability and may also cause workers to leave jobs
early to begin
the doffing and cleaning process.
[0022] Another disadvantage relates to cleaning. Reusable respirators have to
be
properly cleaned, which poses additional logistical challenges. Either the
wearer or other
personnel must be trained for safe handling and cleaning of contaminated
equipment_ This in
turn requires access to cleaning chemicals, cleaning equipment, and facilities
(for cleaning and
storage) as well as training in and compliance with each manufacturers'
defined cleaning
processes. The challenges described in the paragraph above becomes especially
acute in the
context of pathogens. Unlike disposable respirators, reusable respirators
contain a number of
crevices, seams, angles, and other tight areas that may hold reservoirs of
viral particles and
other pathogens. As a result, failure to properly clean these types of
respirators may yield
catastrophic results.
[0023] A further disadvantage of reusable respirators is the lack of
filtration for the
exhaled air. Known reusable respirators are primarily for non-pathogenic
industrial use. The
lack of a filter for exhaled air is a factor that generates significant risk
to others during a
pandemic. Specifically, an asymptomatic or pre-symptomatic infected wearer
will expel
aerosolized particles that can be inhaled by others and/or contaminate
surfaces as they
eventually land, including skin and clothes of others, as well as tables, door
handles, etc.
[0024] Another disadvantage of reusable respirators relates to visibility.
Known
reusable respirators obscure the face of a wearer behind a plurality of layers
of plastic and
elastomer. The use of opaque plastics means that other persons cannot observe
the facial
expressions and demeanor of a wearer. Further, due to incorporating thick
elastomerics and
plastics, reusable respirators tend to significantly distort and dampen the
voice of a wearer.
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This disadvantage requires that the wearer speak slowly and extra loudly to be
intelligible,
which is an inefficient process that quickly fatigues a wearer.
[0025] Although they offer improved fit and comfort and a better air seal than
disposable respirators, the significant incremental cost, logistical needs,
contamination risk,
and poor communication capability of reusable respirators renders these
products inappropriate
for long-term use in a wide variety of occupations and environments.
SUMMARY
[0026] A respirator mask for long-term use is disclosed herein. The example
respirator
mask includes a transparent lens that is connected to or otherwise integrally
formed with a
frame. The user of a transparent lens enables a wearer's facial expressions
and mouth
movement to be seen by others, which improves social interaction and
communication,
especially in medical or childcare environments. The respirator mask is
configured to be placed
over a wearer's nose, cheeks, and chin, thereby providing an air-tight seal.
However, the
positioning of the respirator mask under a wearer's eyes enables a wearer to
have unobstructed
vision and improved comfort. The positioning of the respirator mask under a
wearer's eyes
also enables a wearer to wear their preferred eyewear or prescription glasses
without issue.
[0027] As described herein, the respirator mask has side sections that are
positioned
adjacent to a wearer's cheeks. Inhalation filter assemblies are connected to
each of the side
sections to enable air to be pulled inside of the respirator mask. Air flow
from the inhalation
filter assemblies to a wearer's nose pulls fresh, cool air across the wearer's
face, providing
additional comfort. An exhalation filter assembly is connected to a bottom of
the respirator
mask around a chin area. The downward positioning of the exhalation filter
assembly enables
accumulated moisture and sweat to be expelled from inside of the respirator
assembly. Further,
the downward positioning of the exhalation filter assembly pushes expelled air
downward
instead of outward, thereby preventing possible contamination/infection of
other people.
[0028] In some embodiments, the exhalation and inhalation filter assemblies
have the
same shape and dimensions. This enables the same type of filter media to be
used for all of the
assemblies. As discussed herein, the filter media of the filter assemblies is
removable for
cleaning or disposable for replacement.
[0029] In light of the disclosure herein and without limiting the disclosure
in any way,
in a first aspect of the present disclosure, which may be combined with any
other aspect listed
herein, a respirator mask apparatus including a transparent lens integrated
with a transparent
frame (or a transparent lens that also operates as a frame). The transparent
frame includes a
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top section including a nose bridge to contact a wearer's nose, and left and
right sections
respectively connected to the top section to contact the wearer's checks. Each
of the left and
right sections includes at least one aperture. The transparent frame also
includes a bottom
section including a protrusion to contact the wearer's chin and at least one
aperture and an
elastomeric lip around a perimeter of the transparent frame configured to
provide an air seal
with a face of the wearer. The respirator mask apparatus also includes a first
inhalation filter
assembly connected to an external side of the left section to enclose the at
least one aperture, a
second inhalation filter assembly connected to an external side of the right
section to enclose
the at least one aperture, and an exhalation filter assembly connected to an
external side of the
bottom section to enclose the at least one aperture.
[0030] In a second aspect of the present disclosure, which may be combined
with any
other aspect listed herein, each of the first and second inhalation filter
assemblies and the
exhalation filter assembly include filter media, a base section configured to
receive the filter
media, and a filter cap removably connected to the base section to retain the
filter media against
the base section.
[0031] In a third aspect of the present disclosure, which may be combined with
any
other aspect listed herein, each of the first and second inhalation filter
assemblies includes a
first check valve facing an inside of the apparatus or integrated with the
base section of the
respective filter assembly or the respective left or right section, the check
valve configured to
enable one-way air communication into the apparatus.
[0032] In a fourth aspect of the present disclosure, which may be combined
with any
other aspect listed herein, the exhalation filter assembly includes a second
check valve located
between the filter media and the bottom section of the frame or integrated
with the base section
of the exhalation filter assembly or the bottom section of the frame, the
check valve configured
to enable one-way air communication out of the apparatus.
[0033] In a fifth aspect of the present disclosure, which may be combined with
any
other aspect listed herein, the first and second check valves are reversible
or adjustable to
change an air-flow direction or air-flow resistance.
[0034] In a sixth aspect of the present disclosure, which may be combined with
any
other aspect listed herein, the filter cap has at least one opening to enable
air to pass through to
the filter media.
[0035] In a seventh aspect of the present disclosure, which may be combined
with any
other aspect listed herein, each of the filter assemblies are configured to
accept different types
or sizes of filter media.
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[0036] In an eighth aspect of the present disclosure, which may be combined
with any
other aspect listed herein, a first type or size of filter media are used with
the first and second
inhalation filter assemblies and a second type or size of filter media is used
with the exhalation
filter assembly.
[0037] In a ninth aspect of the present disclosure, which may be combined with
any
other aspect listed herein, the filter media includes two outer layers
configured for structural
support and a third inner layer configured for viral and bacterial filtration.
[0038] In a tenth aspect of the present disclosure, which may be combined with
any
other aspect listed herein, at least one of the filter assemblies is replaced
by an adaptor that
facilitates a connection to at least one of a third-party filter media or a
third-party filter
assembly.
[0039] In an eleventh aspect of the present disclosure, which may be combined
with
any other aspect listed herein, the positioning of the exhalation filter
assembly is configured to
enable accumulated moisture and sweat to flow downward out of an inside of the
apparatus
and enable exhaled air to flow downward preventing external contamination of
others.
[0040] In a twelfth aspect of the present disclosure, which may be combined
with any
other aspect listed herein, the transparent lens has a bulbous shape
configured to prevent contact
between lips and the nose of the wearer.
[0041] In a thirteenth aspect of the present disclosure, which may be combined
with
any other aspect listed herein, the transparent lens includes at least one of
dual parallel lenses
with an air gap between the lenses or dual parallel lenses with a second lens
including a mini-
lens located inside of the apparatus.
[0042] In a fourteenth aspect of the present disclosure, which may be combined
with
any other aspect listed herein, the transparent lens has a thickness that is
less than 3.0 mm to
minimize vocal distortion and decibel loss.
[0043] In a fifteenth aspect of the present disclosure, which may be combined
with any
other aspect listed herein, the transparent lens contains Acoustic Resonant
Micro-Surfaces
("ARMS") that reduce distortion and decibel loss.
[0044] In a sixteenth aspect of the present disclosure, which may be combined
with any
other aspect listed herein, the first inhalation filter assembly is positioned
at the left section and
the second inhalation filter assembly is positioned at the right section to
enable inhaled air to
pass over and cool the wearer's face.
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[0045] In a seventeenth aspect of the present disclosure, which may be
combined with
any other aspect listed herein, each of the left and right sections includes
at least one harness
slot to receive a strap of a harness.
[00461 In an eighteenth aspect of the present disclosure, which may be
combined with
any other aspect listed herein, the strap includes ultrasonic welds to enable
unused portions of
the strap to be removed.
[0047] In a nineteenth aspect of the present disclosure, which may be combined
with
any other aspect listed herein, base sections of the first inhalation filter
assembly, the second
inhalation filter assembly, and the exhalation filter assembly have the same
dimensions to
enable interchangeability or removal of check valves.
[0048] In a twentieth aspect of the present disclosure, which may be combined
with
any other aspect listed herein, the top section is configured to sit below a
wearer's eyewear.
[0049] In a twenty-first aspect of the present disclosure, which may be
combined with
any other aspect listed herein, a respirator mask apparatus includes a
transparent lens integrated
with a frame. The frame includes a top section including a nose bridge to
contact a wearer's
nose, left and right sections respectively connected to the top section to
contact the wearer's
checks, each of the left and right sections including at least one aperture,
and a bottom section
including a protrusion to contact the wearer's chin and at least one aperture.
The apparatus
also includes a first inhalation filter assembly connected to an external side
of the left section
to enclose the at least one aperture, a second inhalation filter assembly
connected to an external
side of the right section to enclose the at least one aperture, and an
exhalation filter assembly
connected to an external side of the bottom section to enclose the at least
one aperture. Each
of the first and second inhalation filter assemblies and the exhalation filter
assembly include
filter media, a base section configured to receive the filter media, a filter
cap removably
connected to the base section to retain the filter media against the base
section, and a check
valve located between the filter media and the base section or integrated with
the base section.
[0050] In a twenty-second aspect of the present disclosure, any of the
structure and
functionality disclosed in connection with Fig. 1 may be combined with any of
the other
structure and functionality disclosed in connection with Figs. 2 to 9.
[0051] In light of the present disclosure and the above aspects, it is
therefore an
advantage of the present disclosure to provide a respirator mask that improves
air flow for a
wearer and prevents an accumulation of sweat and moisture.
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[0052] It is another advantage of the present disclosure to provide a
respirator mask
with disposable or removable filter media to extend usage without degrading
air flow filtering
and performance.
[00531 It is a further advantage of the present disclosure to provide a
respirator mask
that is comfortable to wear, thereby reducing a number of times a wearer
inadvertently touches
or adjusts the mask.
[0054] It is still another advantage of the present disclosure to provide a
respirator mask
with identical inhalation and exhalation assemblies to enable one type of
filter media to be
used.
[0055] It is still a further advantage of the present disclosure to provide a
respirator
mask with a downward facing exhalation filter assembly to enable moisture,
sweat, and exhaled
air to flow downward out of the mask.
[0056] It is still a further advantage of the present disclosure to provide a
respirator
mask that enables a wearer to mix-and-match filter types and sizes for
inhalation and exhalation
based on an end-use application.
[00571 Additional features and advantages are described in, and will be
apparent from,
the following Detailed Description and the Figures. The features and
advantages described
herein are not all-inclusive and, in particular, many additional features and
advantages will be
apparent to one of ordinary skill in the art in view of the figures and
description. Also, any
particular embodiment does not have to have all of the advantages listed
herein and it is
expressly contemplated to claim individual advantageous embodiments
separately. Moreover,
it should be noted that the language used in the specification has been
selected principally for
readability and instructional purposes, and not to limit the scope of the
inventive subject matter.
BRIEF DESCRIPTION OF THE FIGURES
[0058] Fig. 1 is a perspective view of a respirator mask, according to an
example
embodiment of the present disclosure.
[0059] Fig. 2 is a front view of the respiration mask of Fig. 1, according to
an example
embodiment of the present disclosure.
[0060] Fig. 3 is a rear view of the respiration mask of Figs. 1 and 2,
according to an
example embodiment of the present disclosure.
[0061] Fig. 4 is a side view of the respiration mask of Figs. 1 to 3,
according to an
example embodiment of the present disclosure.
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[0062] Fig. 5 is a diagram of an example strap that may be connected to the
respirator
mask of Figs. 1 to 4, according to an example embodiment of the present
disclosure.
[0063] Fig. 6 is a top-down view of the respiration mask of Figs. 1 to 4,
according to
an example embodiment of the present disclosure.
[0064] Fig. 7 is a bottom-up view of the respiration mask of Figs. 1 to 4,
according to
an example embodiment of the present disclosure.
1100651 Fig. 8 is a perspective view of the respirator mask of Figs. 1 to 4,
according to
an example embodiment of the present disclosure.
[0066] Fig. 9 is a rear view of the respirator mask of Figs. 1 to 4, according
to an
example embodiment of the present disclosure.
DETAILED DESCRIPTION
[0067] A respirator mask is disclosed herein. The example respirator mask is
configured to improve air flow around a wearer's face, thereby reducing
moisture and heat
accumulation and improving comfort. The respirator mask includes three filter
assemblies for
enclosing a same type or different types/sizes of filter media. The filter
assemblies may be
opened, enabling disposable filter media to be replaced or non-disposable
filter media to be
cleaned. The use of disposable or removable filter media enable the respirator
mask to operate
at a high level for long-use durations to provide air filtering without
degrading air flow.
1100681 As disclosed herein, the respirator mask is configurable based on a
particular
application and/or environment. For example, the respirator mask accepts
different types
and/or sizes filter media for medical applications, construction applications,
manufacturing
applications, etc. Representative configurations of the respiration mask
include use in sterile
fields and non-sterile fields. It should be appreciated that the disclosed
respirator mask may
be used in any application in which air filtering is needed.
[0069] Fig. 1 is a diagram of a respirator mask 100, according to an example
embodiment of the present disclosure. The respirator mask 100 includes a frame
102 that
supports a transparent lens 104. In some embodiments, the lens 104 may be
connected to the
frame 102. In other embodiments, the lens 104 may be integrally formed with
the frame 102.
Further, the frame 102 may be transparent or opaque. The lens 104 is
configured to be clear to
enable other individuals to view facial expressions or mouth movement of a
wearer. The frame
102 and/or the transparent lens 104 may include plastic, transparent plastic,
glass, pl exigl ass,
rubber or other elastomeric material, or combinations thereof
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[0070] In some embodiments, an elastomeric lip 106 is connected to or
integrally
formed with the frame 104. The elastomeric lip 106 is placed around a
perimeter of the frame
104 and is configured to provide an air seal when pressed against a face of a
wearer. The
elastomeric lip 106 may be permanently connected to the frame 104 or
detachable for
cleaning/replacement. In some instances, the elastomeric lip 106 may be three-
dimensionally
printed to conform to a scan of a wearer's face.
[0071[ In the illustrated example, the frame 102 includes a top section 110, a
left
section 112, a right section 114, and a bottom section 116. The top section
110 of the frame
102 includes a nose bridge 118 and is connected to the left section 112 and
the right section
114. The nose bridge 118 includes an arch that is configured to receive and/or
contact a
wearer's nose. The left section 112 and the right section 114 curve inward
towards a wearer's
face and are configured to contact or be adjacent to a wearer's cheeks. The
left section 112
and the right section 114 each include at least one aperture or cutout to
enable air to pass
through.
[0072] The bottom section 116 of the frame 102 is connected to the left
section 112 and
the right section 114. The bottom section 116 includes a protrusion to
accommodate or
otherwise provide for placement at a wearer's chin. The bottom section 114
also includes at
least one aperture to enable air to pass through.
[0073] As shown, a perimeter of the frame 102 extends from a bridge of a
wearer's
nose to their cheek bones and below their chin. The frame 102 is below the
wearer's eyes to
provide unrestricted visibility. In another embodiment, the top section 110 of
the frame 102
extends to a wearer's forehead to provide a full-face respirator.
[0074] Fig. 1 also shows that the respirator mask 100 includes a first
inhalation filter
assembly 120 that is connected to an external side of the left section 112 to
enclose the at least
one aperture. The respirator mask 100 also includes a second inhalation filter
assembly 122
connected to an external side of the right section 114 to enclose the at least
one aperture.
Further, the respirator mask 100 includes an exhalation filter assembly 124
connected to an
external side of the bottom section 116 to enclose the at least one aperture.
[0075] The filter assemblies 120 to 124 are more readily visible in Figs. 2
and 3, which
respective show a front view and a rear view of the respirator mask 100 of
Fig. 1, according to
an example embodiment of the present disclosure. As shown, each of the filter
assemblies 120
to 124 includes a base section (shown respective as base sections 126a, 126b,
and 126c) that
connects to a respective section 112, 114, and 116 of the frame 102. The base
sections 126a,
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126b, and 126c are configured to cover or otherwise enclose the apertures of
the respective
sections 112, 114, and 116 of the frame 102.
[0076] In an embodiment, each of the base sections 126a, 126b, 126c includes a
gland.
In this embodiment, the sections 112, 114, and 116 includes an elastomeric
sleeve. The base
sections 126a, 126b, 126c are attached and sealed to the frame 102 by
stretching the elastomeric
sleeve over and around the respective glands.
1.00771 In another embodiment, the base sections 126a, 126b, and 126c are
threaded.
Additionally, the sections 112, 114, and 116 each include a locking ring to
contain the mating
thread for securement to the threads of the base sections 126a, 126b, and
126c. The sections
112, 114, and 116 may include a gasket at the connection point to create an
air-tight seal. It
should be appreciated that other components may be used, such as chemical
adhesives, to
connect the base sections 126a, 126b, and 126c to the respective sections 112,
114, and 116 of
the frame 102.
[0078] The filter assemblies 120, 122, and 124 also each include a filter cap
(shown
respective as filter caps 128a, 128b, and 128c). The filter caps 128a, 128b,
and 128c are
removably connected to the respective base sections 126a, 126b, and 126c. In
some
embodiments, the filter caps 128a, 128b, and 128c may be connected via screw
threads or a
snap connector to the respective base sections 126a, 126b, and 126c.
[0079] The filter caps 128a, 128b, and 128c are configured to retain a
respective filter
media 130a, 130b, and 130c against the base sections 126a, 126b, and 126c. In
other words,
the filter caps 128 and base sections 126 sandwich a respective filter media
130. The base
sections 126 may include a recess to accept or receive the filter media 130,
which is held in
place by the filter cap 128.
[0080] In the illustrated embodiments, the filter caps 128 have an open
honeycomb
pattern to enable air and/or moisture to pass through. In other embodiments,
the filter caps 128
may have other patterned openings to enable air to pass through while
retaining the filter media
130 in place. For example, the filter caps 128 may have circular openings,
triangular openings,
square openings, a grid, a decorative pattern such as a company logo, etc.
[0081] The filter media 130 may include industrial-grade N95 filter media. In
other
embodiments, the filter media 130 includes P100 filter media to enable the
respirator mask 100
to provide protection against smoke and oil-based particulates, such as during
wildfire season.
In yet other embodiments, the filter media 130 may have another rating based
on an end-use
application.
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[0082] Known filter media, such as traditional N95 filters, utilize multiple
layers
(often six or more) of increasingly fine filtration to capture particulates
ranging from coal dust
to virus-laden microdroplets less than 100th of a millimeter in size with two
outside layers
to provide structural support and, optionally, a splash barrier. Each
additional layer of
filtration increases breathing resistance and pressure loss. However, purely
for purposes of
pandemic protection, the layers of filtration for the larger particulates
(like coal and saw dust)
provide no benefit. Including these layers in the known filter media decreases
air flow and
increases heat and humidity for a wearer, which in turn increases the
likelihood that a
wearer will engage in non-compliant behavior, such as momentarily lifting the
respirator mask
to breath without restriction. In some instances, the filter media 130
includes three layers. A
first two outer layers are configured to provide structural support and,
optionally, a
splash barrier. A third inner layer is configured to provide viral and
bacterial filtration. The
use of fewer layers compared to known filter media decreases breathing
resistance and pressure
loss while providing substantial filtration protection.
[0083] The filter media 130 may include pleats, similar to that of an air-
conditioner
filter, to create more surface area to help promote air flow. The filter media
130 may have a
circular shape corresponding to the filter assemblies 120, 122, and 124.
Alternatively, the filter
media 130 may have a bulbous shape to increase a filtration surface area. In
some
embodiments, a shape of the filter media 130 channels accumulated moisture to
a base of the
respective filter assembly 120, 122, and 124.
[0084] In some embodiments, an elastomeric grommet is connected to a perimeter
of
the filter media 130. The elastomeric grommet helps ensure an air seal within
the filter
assemblies 120, 122, and 124. The grommet may be removably connected to the
filter media
130 to enable replacement. In some instances, the grommet may be integrally
formed or
connected to the base section 126. In these instances, the grommet may connect
to or otherwise
form a seal with the base section 126 when the filter cap 128 is connected.
The grommet may
provide structural rigidity for the filter media 130.
[0085] In some embodiments, the filter assemblies 120, 122, and 124 may be
omitted.
Instead, a grommet and filter media 130 may be inserted into the one or more
apertures of the
sections 112, 114, and 116 of the frame 102. For example, the grommet may be
press-fittingly
inserted into the apertures of the frame 102. The apertures may include a
structure that mates
with the grommet to form an air-tight seal. In an example, the grommet may
include a groove
or channel around an external face. An edge of the aperture of the frame 102
is sized to fit
within the groove of the grommet to secure the filter media 130 to the frame.
In another
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example, the grommet may include a groove or channel around an internal face.
An edge of
the aperture of the frame 102 is sized and curved outward to fit within the
groove of the
grommet to secure the filter media 130 to the frame 102.
[0086] In the illustrated example, a center or near-center of the filter media
130 is
configured to be aligned with the one or more apertures of the sections 112,
114, and 116 of
the frame 102. This configuration forces inhaled air to pass through the
filter media 130a and
130b before entering an inside of the respirator mask 100. This configuration
also forces
exhaled air to pass through the filter media 130c to exit the respirator mask
100.
[0087] The filter media 130 may be disposable. In these embodiments, the
filter media
130 may be periodically replaced to ensure normal air flow and particle
entrapment.
Alternatively, the filter media 130 may be removable for cleaning and
reinstalled. Further, the
removability of the filter media 130 enables a wearer to adapt the respirator
mask 100 for
different end-user applications by installing different types of filter media
130.
[0088] Figs. 1 to 3 show the filter assemblies 120, 122, and 124 as having a
circular
shape. In other embodiments, the filter assemblies 120, 122, and 124 may have
other shapes.
For example, the filter assemblies may have ovular shapes, rectangular shapes,
triangular
shapes, pentagonal shapes, etc.
[0089] In some embodiments, the filter assemblies 120, 122, and 124 include a
respective check valve 132a, 132b, and 132c. The inhalation filter assemblies
120 and 122
may include a first check valve 132a and 132b that is configured to provide
one-way air
communication into the respirator mask 100. Further, the exhalation filter
assembly 124 may
include a second check valve 132c that provides one-way air communication out
of the
respirator mask 100.
[0090] The first check valves 132a and 132b are configured to remain in an
open state
when a wearer draws a breath, pulling air into the respirator mask 100. The
first check valves
132a and 132b are configured to close when the wearer exhales. The second
check valve 123c
is configured to remain in a closed state when a wearer draws a breath.
Additionally, the second
check valve 132c is configured to open when the wearer exhales enabling air
and moisture to
exit the respirator mask 100.
[0091] As shown in Fig. 3, the check valve 132c for exhalation is located
outside of the
respirator mask 100 between the respective filter media 130 and the respective
base section
126. Additionally, the check valve 132a and 132b for inhalation are located on
an opposite
side of the base section 126a and 126band face the inside the respirator mask
100. In some
embodiments, the check valves 132 may be integrally formed into or otherwise
connected to
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the apertures of the respective sections 112, 114, and 116 of the frame 102.
Alternatively, the
check valves 132 may be integrally formed into or otherwise connected to the
base sections
126 of the filter assemblies 126a, 126b, and 126c. In yet alternative
embodiments, the check
valves 132 may be integrated with the filter media 130.
[0092] The check valves 132 may be permanently connected or may be removable.
Further, in some embodiments, the check valves 132 may have a mushroom shape
to provide
for a one-way flow of air. Moreover, the check valves 132 may be closed or
partially closed
by (i) rotating a portion of a valve housing, (ii) pushing down a cap with a
living hinge to seal
a top of the valve, or (iii) pressing the valve body down into its housing,
which closes a gap
through which air communicates. In addition to above, the check valves 132 may
be reversible
to change a direction of airflow. The reversible nature of the check valves
132 (and positioning
related to the base section 126) enables any of the assemblies 120, 122, and
124 to be easily
switched between inhalation and exhalation.
[0093] While reference is made to check valves 132, it should be appreciated
that any
type of valve may be used. For example, the valves may include a diaphragm or
membrane
valve. In other embodiments, the valves may include solenoid valves or any
other type of air
valve. Further, an actuator on the valve is configured to actuate at pressures
associated with
inhaling and exhaling so as to not increase air-flow resistance for a wearer.
[0094] It should be appreciated that the base sections 126a, 126b, and 126c of
the filter
assemblies 120, 122, and 124 have the same or similar shapes and dimensions at
a point of
connection with the respective sections 112, 114, and 116 of the frame 102.
The similarity of
the base sections 126a, 126b, and 126 enables mixing and matching of the
filter media 130.
Such a configuration also enables a position of the check valves 132 to be
reversed to enable
exhaled air to be provided through the assemblies 120 and 122 while inhaled
air is pulled
through the assembly 124.
[0095] As shown in Figs. 1 to 3, the inhalation filter assemblies 120 and 122
are located
on the frame 102 above each cheek of a wearer. This positioning enables
inhaled air to flow
across the wearer's cheeks to their nose and mouth. This air flow across their
face cools,
dehumidifies, and removes excess moisture.
[0096] Additionally, the exhalation filter assembly 124 is located on the
frame 102 at
or near the chin of a wearer. The positioning of the exhalation filter
assembly 124 at the chin
pushes exhaled air downward, thereby reducing the distribution of the air
after it leaves the
respirator mask 100. This downward (rather than forward) direction for
exhaling air reduces
possible contamination and exposure of others in the event the wearer has a
virus or respiratory
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infection. Further, the shape of the bottom 116 of the frame 102 is configured
to channel
moisture to the exhalation filter assembly 124. The accumulated moisture may
then be pulled
by gravity and/or pushed by exhaled air through the check valve 132c and out
of the respirator
mask 100.
[0097] In some embodiments, the frame 102 forms a solid surface that follows
the
complex curves that compose a wearer's face. As shown in Figs. 1 to 3, the
frame 102
protrudes furthest from the nose and mouth of a wearer. In some embodiments,
to maximize
surface area, the transparent lens 104 (supported by the frame 102) is
configured to protrude in
a bulbous manner from the wearer's face. Fig. 4 is a side view of the
respiration mask 100 of
Figs. 1 to 3, according to an example embodiment of the present disclosure. As
shown, the
frame 102 and lens 104 protrude away from a wearer's nose and mouth, providing
additional
volume for air movement. Further, any moisture that accumulates on the lens
104 is located
away from the wearer and directed to flow to the exhalation filter assembly
124.
[0098] Fig. 4 also shows that the sections 112 and 114 of the frame 102 may
include
slots 402 and 404 for receiving one or more straps. While two slots 402 and
404 are shown, it
should be appreciated that the sections 112 and 114 may omit slots, may
include a single slot,
or may include additional slots. Moreover, the slots 402 and 404 may be formed
from one or
more plastic parts connected to (by overmolding, for example) the frame 102 to
provide
additional resistance against friction from the straps. The straps that are
received in the slots
402 and 404 are configured to secure the respirator mask 100 to a head of a
wearer.
[0099] In an example, a strap for the lower slot 404 travels under a wearer's
ear to a
back of their neck. Additionally, a strap for the upper slot 402 travels above
a wearer's ear to
a top-rear corner of their head. The upper strap may split into two or more
segments at the top-
rear corner of the wearer's head. One or more of these segments are located at
the rear of the
head and one or more these segments are located at the top of the head.
Together, the segments
may form a harness that distributes pressure over a wider area and helps to
secure the respirator
mask 100 from multiple directions. Alternatively, the upper strap may attach
to a plastic
headgear with a preformed split that performs a weight distribution function.
[00100]
Fig. 5 is a diagram of an example strap 500 that may be looped through
the slots 402 or 404 of Fig. 4, according to an example embodiment of the
present disclosure.
The strap 500 may include a knit elastic material and include a rectangular
ring (or similar part)
for length/tension/fit adjustment. The strap 500 may include one or more
ultrasonic welds that
enable excess sections of the strap to be easily removed. In other
embodiments, the ultrasonic
welds may be omitted. In some instances, a lower strap may include a quick
release that
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enables a wearer to temporarily flip the respirator mask 100 up on their head
to, for example,
quickly drink water before resuming work.
[00101]
Fig. 6 is a diagram of a top-down view of the respirator mask 100 of
Figs. 1 to 4, according to an example embodiment of the present disclosure.
This perspective
shows a clearer view of the check valve 132c of the exhalation filter assembly
124. Fig. 6 also
shows in some embodiments, the frame 102 may include at least on point of
attachment 602
for a splash guard. In some embodiments, the splash guard may be integrally
formed with the
frame 102. Further, the filter assemblies 120, 124, and 126 may each include
an attachment
point for a splash guard to cover the filter media 130.
[00102]
In some embodiments, the frame 102 may include an attachment point
for a wireless microphone, or include a wireless microphone. In this
embodiment, a wearer
may use a speakerphone on a smartphone to broadcast their speech. The point of
attachment
may be located inside the frame 102 and out of a line of sight of the wearer.
[00103]
Fig. 7 is a bottom-up view of the respirator mask 100 of Figs. 1 to 4,
according to an example embodiment of the present disclosure. Fig, 7 shows how
the
exhalation filter assembly 124 is configured to point downward. This downward
direction
causes exhaled air and moisture to flow downward out of the respirator mask
100 to prevent
widespread dispersion. The illustration also shows how the filter assemblies
120, 122, and 124
are connected to the frame 102 at the respective sections 112, 114, and 116.
11001041
Fig. 8 is a perspective view of the respirator mask 100 of Figs. 1 to 4,
according to an example embodiment of the present disclosure. The illustrated
embodiment
shows one example of the check valve 132a for the inhalation filter assembly
120. The
illustrated embodiment also shows that the frame 102 is transparent. In some
instances, the
frame 102 may include a ring of biomedical compatible plastic that conforms to
the complex
curves of a wearer's face. Alternatively, a portion or all of the frame 102 is
coated with a
biocompatible elastomeric material. The slots 402 and 404 for the straps may
also be coated
with the biocompatible elastomeric materials to secure the straps near the
rear of the frame 102.
To absorb wear, in an embodiment the slots 402 and 404 may be manufactured
from plastic
and designed -proud," which is to say that the edges of the material protrude
beyond the surface
of the underlying frame 102 in order to lift the straps away from the softer
material of the frame
102.
[00105]
Further, the transparent lens 104 may be comprised of a biocompatible
material that enables a wearer to write and draw on it with an erasable marker
and to later erase
those markings in favor of new markings. The transparent lens 104 may be thin
enough that a
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wearer's voice communicates through the material to the ears of others with
minimal distortion
and decibel loss. The transparent lens 104, for example, may have a thickness
of less than 3
mm, preferably around 1 mm. The thinness of the lens 104 minimizes distortion
and decibel
loss. The lens 104, in some embodiments, may include two parallel lenses with
an air gap there
between, with the second lens closest to a wearer either a duplicate of the
first lens 104 or,
alternately, a smaller version of the first lens 104 designed to only cover
the area most prone
to fogging.
[00106]
In a further example, the transparent lens 104 contains Acoustic
Resonant Micro-Surfaces (ARMS) that reduce distortion and decibel loss. In an
example, the
ARMS include a plurality of grooves in the lens 104 that create a set of
surfaces parallel to the
face of the wearer and someone standing directly in front of the wearer. In an
example, a
plurality of grooves has a uniform in length, of 21.5mm that are organized in
either horizontal
or vertical parallel lines. In other embodiments, a plurality of grooves are
organized in
horizontal lines of various lengths in the portion of the lens 104 in front of
the wearer's mouth,
ideally with the following values ¨ 11 : 13.8 : 15.2 : 17.1 : 21.5 34 : 38 :
43 : 38 : 34 21.5 :
17.1 : 15.2 : 13.8 :11 as measured in millimeters.
[00107]
Fig. 9 is a rear view of the respirator mask 100 of Figs. 1 to 4,
according
to an example embodiment of the present disclosure. The illustrated example
shows a clearer
view of the check valves 132a, 132b, and 132c of the respective filter
assemblies 120, 122, and
124. Fig. 9 also shows corresponding apertures 902, 904, and 906 of the
respective sections
112, 114, and 116 of the frame 102. As shown, the apertures 902, 904, and 906
are aligned
with the check valves 132a, 132b, and 132c to provide for one-way air flow
into or out of the
respirator mask 100.
[00108]
As shown in Fig. 9, the materials of the respirator mask 100 may be
cleaned and/or sterilized by running through a dishwasher on a hot cycle.
Further, a shape of
the frame 102 and/or lens 104 and corresponding points of attachment lack any
crevices or
small areas that would prove difficult to reach in a liquid bath or would
otherwise provide
surfaces difficult to clean and sterilized by approved methods. The disclosed
respirator mask
100 accordingly is easy to maintain and clean, thereby extending its useful
life.
[00109]
The respirator mask 100 could be configured to replace one or more of
the inhalation filter assembly 120 and 122 and the exhalation filter assembly
124 with adapters
that enable a wearer to use the broad array of specialty filters from 3MC ,
Honeywell , and
other manufacturers. Doing so provides a wearer with both greater breadth of
filter offerings
and a deeper, more redundant supply chain during a time of emergency.
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Filter Media Interchangeability Embodiment
[00110]
As described above, the filter assemblies 120, 122, and 124 include the
filter media 130. The base sections 126 and the filter caps 128 are configured
to receive or
house filter media 130 of different sizes. For example, the base sections 126
and the filter caps
128 may house circular filter media 130 having a diameter between 30 mm and
200 mm. It
should be appreciated that the filter assemblies 120, 122, and 124 are
configured to enable a
wearer to mix-and-match different filter media 130 based on an end-use
application or personal
preference. For example, a wearer may select two 120 mm inhale filters and one
60 mm or 80
mm exhale filter for a dusty environment. In another example, a wearer may
select two 60 mm
inhalation filter media 130 and one 80 mm filter media 130 for exhaling. The
possible filter
media 130 combinations are virtually endless.
[00111]
In a further example, the filter assemblies 120, 122, and 124 are
produced in various sizes and can be changed out depending on the present need
of a wearer.
In an example, the base section 126 and the filter cap 128 are designed to
support a smaller
replaceable filter media (60 mm for example) suitable for pathogenic
protection during light-
duly, non-aerobic tasks, such as indoor office work, teaching in a classroom,
or running
errands. In an alternate example, the base section 126 and the filter cap 128
are designed to
support a larger replaceable filter media (80, 120, and 150 mm for example)
that are sufficient
for heavier-duty, more aerobic activity, such as jogging or spending extended
periods in a
smoke-filled outdoor environment.
[00112]
In some embodiments, at least one of the filter assemblies 120, 122, and
124 may be removed. A third-party filter assembly or a third-party filter
media may instead be
connected to the respective section 112, 114, or 116 of the frame 102. In some
embodiments,
an adapter may be used to facilitate the connection between the section 112,
114, or 116 of the
frame 102 and the third-party filter assembly and/or filter media.
Powered Respirator Mask Field Embodiment
[00113]
In some embodiments, the respirator mask 100 may be used as a
Powered Air Purifying Respirator (PAPR). In these embodiments, the filter
assemblies 120,
122, and 124 may be replaced by a powered fan/filter assembly. In some
embodiments, the
base sections 126 may remain in place and a fan/filter assembly may replace
the filter cap 128
and the filter media 130. A power source for the fan may be integrated into
the cap or located
on a user and connected via wired connection. In some instances, the wires may
be integrated
with the strap 500 to minimize clutter and entanglement.
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[00114]
The PAPR helps create a sterile environment inside the respirator mask
100 even if the mask fits poorly or at least is poorly situated by an inexpert
wearer. The
disclosed respirator mask 100 would be useful in environments that contain an
airborne
pathogen that is highly contagious (like measles) and highly deadly (like
MERS).
Conclusion
[00115]
It should be understood that various changes and modifications to the
presently preferred embodiments described herein will be apparent to those
skilled in the art.
Such changes and modifications can be made without departing from the spirit
and scope of
the present subject matter and without diminishing its intended advantages. It
is therefore
intended that such changes and modifications be covered by the appended
claims.
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