Bubble Seal Facemask

Cross-Reference to Related Applications

This application claims the benefit of five provisional patent applications by the present inventor, a first filed on 17/ JUN/2020, Application # 63/040,460, titled "Air Mask Gasket”; a second filed 06/AUG/2020, Application # 63/061,930, titled "Bubble Seal”; a third filed 29/AUG/2020, Application # 62/706,637, titled "Bubble Seal [+]"; a fourth filed 09/SEPT/2020, Application # 62/706,778, titled "Bubble Seal and Chin Cord”; a fifth filed 17/NOV/2020, Application # 63/198,271, titled "Bubble/Cord Mask"; and a sixth filed 13/JAN/2021, Application #63/199,633, titled "Bubble/Cord Mask Improvements”.

Technical Field

The present invention relates to personal protective equipment, and more particularly to facemasks.

Background Art

The following is a tabulation of some prior art that presently appears relevant:

Application Publications

Patent Number Kind Code Issue Date Patentee

US20130213414 A1 Aug. 22, 2013 Park US20160114197 A1 Apr. 28, 2016 Fichman et al.

Foreign Patent Documents

Patent Number Kind Code Issue Date Patentee

KR200485969 Y1 2018-03-16 KR100936050 B1 2010-01-08 WO2019008161 A1 10 Jan 2019 House WO2018003831 A1 2018-01-04 Nakagawara

The problem with facemasks in general, and disposable facemasks in particular, lose much of their effectiveness because up to about one third of the air leaks around the edges of the mask. The above patent documents are all directed towards solving this difficult problem. However, all of these prior disclosures have at least one of the following three shortcomings: 1) being overly complex and expensive to manufacture and therefore impractical for producing a disposable facemask, 2) being oversimplified or incomplete, thereby failing to address the actual problems involved, or 3) being successful, but inferior solutions.

Park discloses a mask seal that forms an air cushion, but it is a detailed and complex part which is more similar to a typical half mask seal that would far exceed the expense of a disposable mask. In contrast, a sealed cushion concept by Fichman et al. uses simple two-dimensional parts joined together. However, this considerably limits localized fit geometry and also creates a very wide contacts surface against the user's face in order to achieve cushion depth. Also the expense of inflating the cushion has been added. employs a perimeter rubber hose concept, but it's unclear whether it's actually sealed, or like an open section of rubber hose, the wall of the hose provides some resilient deformation. Additionally, there is a separate protrusion bag 152 to seal the nose area, but does not appear to be air-filled.

¾ o|§ ¾o|§ discloses an air portion 120 to assist in mask sealing, but the drawings are simple to the point of diagrammatic and there's no mention of inflation, but there's a concern about gas escaping. In any case, the solution is too complex and expensive, because the gas-escape solution is to make the air portion 120 removable.

House employs an air filled lumen to create a face seal, but also has open cell foam inside the lumen plus a valve that allows the user to control the air pressure. Again, this solution is overly complex and expensive.

To improve sealing Nakagawara discloses a continuous cord that both transverses through the mask and provides ear loops. However, it appears unnecessarily complex. Parts (182, 192) other than the mask body provide for cord transverse. Also, adding complexity and expense, the cord transverses both the bottom and top of the mask.

Summary of the Embodiments

A first embodiment includes a facemask seal comprising a surgical facemask, a bubble (32 ) filled with mobile material such as air, where the bubble is attached near the perimeter of the inside surface of the facemask along the upper portion of the facemask adjacent to the user's nose, and a second similar mirror-image bubble such that the mask has two bubbles, one on each side of the user's nose. The bubbles create an upper mask sealing means.

The first embodiment further includes a heat-welded tunnel (312) through the bottom portion of the mask which can slidably contain an elastic cord (310). The elastic cord replaces the traditional ear loop cords with a single cord. The cord is attached at one upper corner of the mask and then loops around and enters the tunnel to create an ear loop (7). The cord passes through the tunnel exiting on the other side of the mask, then loops around, and is attached at the other upper corner of the mask to create the other ear loop (7). The cord (310) and tunnel (312) create a lower mask sealing means. Pulling the cord in the tunnel region causes the tunnel to fold and collapse laterally, i.e. bunch up like drawn curtains. This elastic tension means allows them mask to elastically expand to fit different faces and accommodate facial movement. The elastic tension also pulls the sides of a mask flat to to provide side sealing means. Certain tunnel geometries are helpful in further improving the seal.

Brief Description of the Drawings

Fig. 1 schematically illustrates surgical mask with bubble;

Fig. 2 schematically illustrates bubble cross-section;

Fig. 3 schematically illustrates angled bubble;

Fig. 4 schematically illustrates corner bubble with pleats;

Fig. 5 schematically illustrates corner bubble on mask; Fig. 6 schematically illustrates pleat detail;

Fig. 7 schematically illustrates pleat refinement side view;

Fig. 8 schematically illustrates pleat refinement top view;

Fig. 10 schematically illustrates pleat refinement perspective view;

Fig. 15 schematically illustrates N95 with partial bubble;

Fig. 16 schematically illustrates N95 with full perimeter bubble;

Fig. 17 schematically illustrates N95 cross-section with bubble;

Fig. 18 schematically illustrates N95 cross-section with floating bubble; Fig. 19 schematically illustrates surgical mask with cord and tunnel;

Fig. 20 schematically illustrates cord and tunnel construction;

Fig. 21 schematically illustrates second construction step;

Fig. 22 schematically illustrates alternate tunnel construction;

Fig. 23 schematically illustrates second construction step.

List of Parts

1 mask nose gap 12 angled base 24

2 body nose bridge 12B bend angle 25 outer layer 2A flange 13 pleated corner bubble 30 mid layer 2B 13A top flange 50 left pleated corner bubble 30A inner layer 2C 35 13B bottom flange right pleated corner bubble 30B

3 top 15 bubble body top pleated bubble 32

4 bottom apex 15A left top pleated bubble 32A 5A left side nadir 15B right top pleated bubble 32B 5B right side crown area 15C 55 side pleated bubble 33

6 pleats 40 edge area 15D bubble connector 34

7 ear loop bubble front 16A inside flange 36A

8 top fold bubble back 16B outside flange 36B

9 nose wire shape layer 17 open zone 36C

10 bubble base layer 18 60 crown pleats 40 10A left bubble 45 angled bubble 20 side pleats 42 10B right bubble bend 22 taper pleats 43 pleat apex 45A 20 N95 mask 200 cord 310 pleat nadir 45B hemisphere 202 40 cord tunnel 312 pleat depth 45A mask flange 204 cord containment 310 pleat width 45B hemisphere perimeter 206 tunnel bend A 316 inter-pleat distance 46 neck strap 208 tunnel bend B 317 unfilleted corners 70 25 valve 209 tunnel bend C 318 corner fillet 72 partial perimeter bubble 21045 horizontal direction 320 base apex 78A full perimeter bubble 212 mask welds 330 front base nadir 78B weld attachment 214 first mask welds 332 rear base nadir 78C bubble tube 216 cord weld 336 top pleated bubble mold 90A30 nose bubble 218 second mask welds 334 top pleated bubble mold 90B valve 219 50 horizontal dimension 340 side pleated bubble mold 92A centerline 230 horizontal dimension 342 side pleated bubble mold 92B path radius 232 vertical dimension 344 expansion ridges 94 flange adjacency 234 vertical dimension 346 edge ridges 96 35 flange bubble 240 vertical dimension 348 vacuum hole 98 floating bubble 250 55 mask 401 inflation reduction ridge 100 mask 301 body 402 no ridge 100X body 302

Detailed Description of Embodiments

Disposable surgical facemasks, also known as medical or procedural masks, are common and well-known. Fig 1 shows the mask 1 with the inside surface showing. It has a body 2 with a top 3, bottom 4, left side 5A, and right side 5B. The mask body 2 has three pleats of folded material which unfold to create a three-dimensional, somewhat hemispherical shape.

The top and bottom of the mask have folded material to create a finished edge on the mask and on the Top Mask Fold 8 to create a pocket 8A that traps the nose wire 7 (as shown in Fig 2). The Top and Bottom Mask Folds, and both sides of the mask are heat welded with a series of dots along the entire perimeter of the mask (not shown). The ear loops 7 on each side of the mask, shown as partially cutaway, are also heat welded onto the mask, ear loops 7 may alternately be a set of four open straps tie behind the neck and head, or two the elastic straps that extends behind the neck and head, similar to N95 mask straps. In this second embodiment, seen in Fig. 1, there are two top bubbles 10A and 10B, 10A on the left and its mirror image 10B on the right. These bubbles have a nose gap 12 space in between them at the center (side-to-side) of top 3. A flange 13 at the base of bubbles 10 adjoins the inner surface of the mask's body 2. The top and bottom flange portions are top flange 13A and bottom flange 13B. Figure 1 also shows an area with cross-section marks A-A,

Fig 2 is cross-section A-A. The shows a cross-section of bubble 10 contacting body 2. Bubble 10 is comprised of a shape layer 17 and base layer 18. Base layer 18 contacts the inside surface of body 2. Above that, in the z-axis, is shape layer 17. The cross-section size and shape of shape layer 17 varies depending on where the cross-section is taken along the longitudinal length of bubble 10. This cross-section is taken at the bubble's apex 15A, an area more proximal to the center of the mask. Nadir 15B is in the background of the cross-section at a distal portion of the bubble. The upper portion of bubble body 15, distal from base layer 18, is crown area 15. The lower/side portions of bubble body 15, proximal to base layer 18, is edge area 15D. Flowever, any given cross-section of the bubble 10 will have a flat flange 13 on either side of the curved bubble body 15 portions of the bubble as top flange 13A and bottom flange 13B. The flanges 13 provide an attachment [/welding, bonding, tacking, gluing, sewing] means of attaching the bubble 10 to body 2.

Lexicography

The bracket encapsulation of one or more words or phrases starting with "[/" and ending in "]" is equivalent to stating that at least one of the encapsulated word(s) or phrase(s) may optionally be substituted for, or added to the word or phrase preceding the "[/".

For example, an XXX1 [/XXX2, XXX3] device means an XXX1 device, but optionally may mean an XXX2 device, an XXX3 device is being selected as the disclosure. Alternatively, an XXX1 device may be selected to mean XXX1 and XXX2 devices or XXX1 and XXX3 devices.

Additionally, at least one of the encapsulated word(s) or phrase(s) may optionally be combined with at least one other of the encapsulated word(s) or phrase(s) instead of the preceding word or phrase. For example, instead of an XXX1 device, XXX2 and XXX3 devices may be selected as the disclosure.

Bubble Seal Solution

The materials and method of as a means of manufacturing bubble 1 is similar to Bubble Wrap (trademark name), also known as bubble cushioning or packaging, which traps a layer of air between two layers of plastic (typically polyethylene) and heat welds (or ultrasonic, etc.) the two layers together. Restated, the bubble is a thin film envelope with a volume of air trapped within it. The first manufacturing step, a vacuum forming [/bubble shaping] means, causes one layer of plastic to be deformed by heating and vacuum forming to create the three-dimensional shape which becomes the 3-D body of the bubble. A second film layer, a base [/2nd] layer means, which remains flat, is heat sealed, a sealing means or permanent [/completely, partially, temporarily, reversibly sealing] means, to the first layer at the base of the bubble to enclose and seal the bubble. A bubble wrap bubble has a circular footprint and a hemispherical 3-D shape. If it's a perfect hemisphere, the bubble would be as tall as the circular footprint radius, therefore half as tall as the footprint's diameter (width). Therefore, the height of the bubble is primarily determined by the bubble's footprint. Often the bubble does not have to be a perfect hemisphere and therefore a bubble may be taller or shorter than another bubble with the same footprint (diameter/width). For example, a bubble could be made taller by being comprised of two geometric shapes: an essentially cylindrical vertical wall that adjoins a hemispherical shape such that the apex and the base of the hemisphere are both higher than they would be with just the hemispherical shape (a single geometric shape) comprising the bubble.

Longitudinal Shaping Means

Bubble 10 is similar to it has been elongated such that it has a hollow tube shape whose axial length runs along the y-axis as an elongation [/longitudinal, axial] means. The x-axis footprint (width) is larger proximate to the nose gap 12 and smaller at the distal end.

To act as a bubble (trapping air to maintain its three-dimensional shape), each end of the hollow tubular bubble 10 must have a closure. In this embodiment the closure shape is a hemisphere defined by an approximately 180° semi circle footprint as an end closure means.

This embodiment of bubble 10 is made of two layers of a heat weldable film (for example inexpensive films such as polyethylene, polypropylene or more durable films such as polyurethane film) that are attached (typically by heat welded) to each other. The weld is between shape layer 17 and base layer 18 defines and outlines the bubble 10 perimeter. Lying outside the perimeter is the flange 13 perimeter where the two layers end.

The Bubble Seal Flange is then heat welded to the mask. The Bubble Mask connecting weld points (generally in a similar to the welding used to join components of the medical mask) are represented in FIG 51 as a series of small circles.

Cross-Section

The Fig 2 profile shape (cross-section) of the bubble body 15 is shown as generally hemispherical which is by its inherent geometry is about half (50%) as high (or tall, z-axis) as it's width (x-axis). Which can be referred to as a Height Ratio of about 50%.

A Height Ratio Means

Height Ratio Means: Flowever, the Height Ratio of any given cross-section profile of bubble body 15 may be specified as less than 50%, including 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10% or 5% of bubble body 15's width. Conversely, Height Ratio may be specified as more than 50%, including 55%, 60%, 65%, 70%, 75%, 80%, 85%,

90%, 95%, 100%, 110% or 125% of bubble body 15's width. Variance on the above amounts may be specified as ± 1% or ± 2.5%.

Additionally, a Height Ratio may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 25%, or less than 90%) and/or a range may be specified between any two of these disclosed amounts (such as between 25% and 75%).

Reducing a profile's Height Ratio of can be achieved by using a more elliptical rather than circular bubble body 15 profile (cross-section) and/or defining the intersection angle between bubble body 15's profile and flange 13 as being between nearly parallel to, or perpendicular to flange 13. Alternate Profile Means

Alternate Profile Means: To specify profiles with Height Ratios greater than 50% a more elliptical profile (not shown) should be used because an angle of greater than 90% is more unstable and difficult to manufacture (create an undercut). Somewhat similar to creating an elliptical profile, the High Ratio could be increased by essentially vertical walls (in the z-axis) capped by a hemisphere shape, i.e. raising the hemisphere vertically (not shown).

Therefore, the height of bubble body 15 could be controlled exclusively by changing the height to width ratio such that bubble body 15's width remained consistent while the height of bubble body 15 could increase and decrease from apex to nadir to appropriately accommodate the shape of the users face and eliminate/reduce air gaps between the users face and the mask.

One advantage of maintaining a consistent bubble body 15 width is to provide a consistent flange 13 width, which in turn, would provide a more consistent area for joining the flange 13 to the mask.

In sum, the height modulation of a given bubble body 15 profile can be achieved by modulating its width or its Height Ratio. Additionally, modulating both the Footprint and Height Ratio together, each in varying degrees, may be employed.

Apex-Nadir Ratio Means

Apex-Nadir Ratio Means: Different bubble body 15 profiles along the length of bubble body 15 may have different heights in order to reduce the gap between a users face and the mask, a fit [/face, ergonomic] accommodation means. As seen in Fig 2 bubble body 15 has its highest point or apex close to its proximate end, adjacent to bubble body 15 nose gap12 . Its lowest point, or nadir, is at the distal end.

The height (and width) of the nadir is about half (50%) of the apex in the Fig 2 disclosure. The Apex-Nadir Ratio between them may be specified as less, wherein the nadir's height is about 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the apex's height. Conversely, the Ratio may be specified as greater, wherein the nadir's height is about 30%, 25%, 20%, 15%, 12%, 10%, 8% or 5% of the apex's height. Variance on the above amounts may be specified as ± 1% or ± 2.5%.

Additionally, a Apex-Nadir Ratio can be specified as greater than, or less than, any one of the above disclosed amounts (such as greater than 10%, or less than 75%) and/or specified between any two of the above disclosed amounts (such as 15%-60%).

A shift in height between the apex and the nadir along the longitudinal path between profiles could be linear (creating a cone shape). However, the Fig 1 embodiment shows one option of a nonlinear height and width shift to create a swooping or curving 3-D shape and footprint.

Wall Thickness Means

Wall Thickness Means: The film used to make the bubble (i.e. bubble 10) is 3 mil (.003 inch) thick. Alternately, the film thicknesses may be specified as one or more of the following: 0.01, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2.5, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 9, 10, 12, 15, 20, 25 mil. Variance on the above amounts may be specified as ± 1%, ± 2.5%, ± 5%, or ± 10%.

Additionally, the film thickness may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 1 mil, or less than 10 mill) and/or a range may be specified between any two of these disclosed amounts (such as between 2 and 5 mill).

Minimum Wall Thickness Means: Also, because vacuum forming the film reduces the wall thickness, a minimum wall thickness in the three-dimensional portions (i.e. stretched) of the bubble ( i.e. bubble body 15) will be less than the original film thickness. The minimum wall thickness for the bubble may also, but independently, be specified from the above film thickness alternative dimensions and qualifications above.

Advantages

The advantage of the Bubble Seal solution is that bubble 10 is extremely inexpensive and lightweight. Being lightweight reduces mask slippage by not adding weight. Due to its placement and being a 3-D protuberance, bubble 10 further reduces slippage. Using film material with a tacky grip can reduce slippage even further.

Another advantage of the Bubble Seal is that the air in bubble 10 can move between different portions of the bubble. This allows localized portions of the bubble to conform (in the z-axis) to a greater degree to face and mask contours. Unlike foam, such as weather seal, there is virtually no resistance to localized deformation. Instead there is an overall resistance to deformation that is based on pneumatic equalization throughout the Bubble.

Also, the Bubble Seal is that it does not rely on positive air pressure and so is durable and storable for years.

A further advantage of the Bubble Seal uses a heat sealable material therefore may be heat sealed to the mask.

Still one more advantage of the Bubble Seal is that it is soft and therefore comfortable.

Bubble Deformation

Unlike the thin latex film of a balloon that flexes and stretches and the thin film of bubble 10 flexes, but does not stretch or does not stretch easily enough to be useful.

The reason this matters is that the medical mask is manufactured flat ("Manufactured Configuration"), but the central area at nose gap 12 bends to fit the user's nose. The mask bends by bending nose wire 9 over the bridge (or apex) of the nose ("First Bend") and then bends in the reverse direction at each side of the base of the nose (or nasal nadir) where the nose and cheek intersect ("Second Bend"). The angle ("Bend Angle") of the Second Bend is based on a first plane corresponding to the user's nose and a second plane corresponding to the user's cheek. This is referred to as the mask's User Configuration. The Bend Angle on the inventor's face was found to be about 45°.

This intersection is a major area of air leakage and therefore a place where bubble 10 should fit well.

The Bend Angle of mask must flex from the Manufactured Configuration to about 45° in the User Configuration. Because the Bubble doesn't stretch, the inventor found after multiple prototype failures that the Bubble at the nose- cheek intersection collapses as the mask is bent into the 45° position. [=][=]Bending Bubble

When the mask 1 and bubble 10 are bent into the User Configuration the Bend Angle creates a differential radius in different portions of the Bubble. Base layer 18 and flange 13 of shape layer 17 form the bottom of bubble 10 and constitute the inside radius of the Bend Angle. The top portion bubble 10, Crown area 15C becomes the outside, and larger, radius of the Bend Angle.

In the Manufactured Configuration base layer 18 and crown area 15C are identical in length, but in the User Configuration they are not. The flat length of each becomes a circumferential length dependent on the Bend Angle radius. Because the Bubble Crown's radius is larger than the Bubble Base, it also has a larger circumferential length. To accommodate the need for this larger circumferential length, the Bubble Crown must either stretch or collapse.

Angled Bubble Means

Angled Bubble Means: A solution to this problem is to mold (vacuum-form) shape layer 17 at approximately a 45° angle and then attach and seal base layer 18 while still in the 45° configuration to create angled bubble 20 as seen in Fig 3. This creates a bend inherent in the three-dimensional shape of the Bubble. As seen in Fig 4, angled base 24 is bent at bend angle 25 relative to the angle of base layer 18. In other words, the portion of angled bubble 20 proximal to nose gap 12 is preformed to approximately match the Second Bend in mask 1 when it is in the User Configuration. Therefore, the Bubble Crown does not need to stretch to accommodate this bend, because it has already been stretched (i.e. pre-stretched) when the material was hot and subject to sufficient vacuum force to stretch it into the shape of the Angled Bubble.

To differentiate, a bubble manufactured in a flat, 0°, configuration may be referred to as a Non-Angled Bubble.

Flat Configuration Means

Flat Configuration Means: When the Angled Bubble is flattened for attachment to mask 1, or stored and shipped flat, the bubble angled bubble 20 can be reconfigured (i.e. bent) into a flat configuration to attached to the flat mask 1 and be stored flat. Bubble 20 will wrinkle during storage, but will not be harmed and will return to its full and "puffy" condition when bent back into its original angled orientation.

Bend Angle

As previously disclosed, bend angle 25 is about 45°. Flowever, given the ergonomic variability of individuals, bend angle 25 could be specified as a smaller angle, including 40°, 35°, 30°, 25°, 20°, 15°, and 10°. Conversely, this angle could be specified as an angle greater than 45° including 50°, 55°, 60°, 65°, 70°, 75°, 80°, and 85°. Variance on the above amounts may be specified as ± 1% or ± 2.5%.

Additionally, the bend angle 25 may be specified as greater than, or less than, any one of these disclosed amounts. For example, a bend angle 25 greater than 30°, or a bend angle 25 less than 75°.

Furthermore, a range may be specified between any two of these disclosed amounts For example, a bend angle 25 between 30° and 60°, or between 40° at 70°. Pleated Bending Means

Pleated Bending Means: A strategy for vacuum forming the bubble 10 in a flat (0°) non-angled configuration, yet solving the User Configuration stretching problem involves the use of pleats in bubble body 15.

As shown in Fig 5 a pleated corner bubble 30 with a top pleated bubble 32 has crown pleats 40 on its crown area 15C which allow for the expansion of that portion when bent into the User Configuration. It eliminates or reduces the stretching of the Bubble Crown's material.

Side Bubble Means

Side Bubble Means: Similar to bubble 10, bubbles may be incorporated on the left and right sides of the mask to improve mask sealing. These bubbles may be placed on the sides independently, or may be incorporated as an extension of a bubble on the top of the mask, such as bubble 10. Fig 5 shows a side pleated bubble 33 integrated with a top pleated bubble 32 to form a pleated corner bubble 30. The top and side bubbles are connected at approximately 90° to each other by a bubble connector 34.

Side Pleated Bending Means

Side Pleated Bending Means: Like the top bubble, the side bubbles also have a bending problem when the mask changes from a Manufactured to a User Configuration. Flowever, the bending is different, instead of accommodating the user's nose the side bubble is responding to the sides of the mask becoming curved as the mask is opened from a flat rectangle (Manufactured Configuration) into a semi-hemisphere (User Configuration).

This bending difference, means the top bubble and side bubbles bend, and therefore stretch, in different planes. The top bubble stretches along the crown area 15C, while the side bubble bends along the edge area 15D. Accordingly, side pleated bubble 33 has side pleats 42 along the inside edge of bubble 33. This allows the inside edge of bubble 33 to expand as bubble 33 curves. Because side pleats 42 extend to the bubble base they are more effective if they extend through base layer 18. Because side pleats 42 extend to the bubble base effectiveness improves if they extend through base layer 18. This affects a flange 36 as follows. Bubble 33 has an inside flange 36A and an outside flange 36B, but this embodiment also an area where the pleats 42 are found which has no flange. This is called open zone 36C. It provides a means of accommodating the opening movement of side pleats 42 when mask one is opened to the User Configuration.

Both the crown and edge pleats propagate multiple pleats along the axial length of their respective bubbles.

FIG 6 shows a left pleated corner bubble 30A and a right pleated corner bubble 30B on mask 1. A top bubble longitudinal direction 44 and a side bubble longitudinal direction 45 are also shown. Notice the Fig 6 embodiment is an example of fewer side pleats 42. It's also an example of more tightly distributed, i.e. closer together, set of pleats.

The Fig 1 and 6 embodiments show their respective bubbles generally adjacent to the mask's perimeter.

Air Volume Means

Air Volume Means: If a greater volume of air is desired inside a bubble, the following manufacturing method would be a means of greater volume (not shown). In the first step, an auxiliary bubble is created during the molding and sealing process. A relatively small tunnel would connect the original or main bubble (eg. bubbles 10, 20 and/or 30) and the auxiliary bubble, such that they share a single common air volume. In a second step, the auxiliary bubble would be would be flattened, thereby forcing its air (or any mobile filling material) volume into the main bubble (via the tunnel) and then a second seal would seal off the tunnel and contain the air inside the main bubble.

Curvature Accommodation Means

A Curvature Accommodation Means, whether accomplished by forming the bubble at an angle, the addition of pleats to the bubble, or by other means, may be defined by how much longer, as a ratio, the top surface of the bubble to be elongated during bending ("Elongation Length"), is than the bubble's axial length if/when the bubble is straight.

The Elongation Length may be specified as 5%, 10%, 15%, 20%, 25%, 30%, 35% 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% longer than the Bubble's straight axial length. Variance on the above amounts may be specified as ± 1% or ± 2.5%.

Additionally, the Elongation Length may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 15%, or less than 50%) and/or a range may be specified between any two of these disclosed amounts (such as between 10% and 60%).

Such Curvature Accommodation means can extend beyond a seal for a mask. It is disclosed that any linear or elongated bubble shape may utilize the here-in disclosed means of curvature accommodation for a bubble shape which changes from a straight configuration to a curved or bent configuration. Such means of curvature accommodation also applies to changes from a curved bubble shape to a more angled curve configuration.

FIG 7

Fig 7 shows a top pleated bubble 32A with different bubble body 15 and pleat 6 geometry than the Figs 5 and 6. The Fig 7 embodiment has pleats along the top of the top pleated bubble 32 in a similar fashion as the Fig 5 pleats, but then differ because they connect to and continue down along the sides of the bubble. Accordingly the Fig 7 has crown pleats 40, but the pleats on the side of the bubble are not side pleats 42, because they taper. Therefore, the pleats along the side are taper pleats 43.

Body 15 of the Fig 7 embodiment has a rectangular cross-section with unfilleted corners 70. The sides of body 15 is edge area 15D and the top is crown area 15C. In this embodiment these areas are essentially planar rather than curved with an essentially continuous arcing cross-section, per the Fig 2 embodiment.

Tapered pleats 43 have a tapered or V shape to accommodate and match the difference in circumferential length needed to accommodate folding mask 1 into the User Configuration. Tapered pleat 42B matches the width and depth of crown pleat 40 at their connecting intersection and tapers to flush as it approaches the base of bubble body 15. Pleat width 45B and inter-pleat distance 46 are shown in Fig 7.

Fig 7 also shows right bubble 10B without pleating as an example of a non-pleated option. However the right and left bubbles would generally be symmetric mirror-images of each other. Also, right bubble 10B and left top pleated bubble 32A are joined together as one continuous form (i.e. envelope) with a continuous unitary cavity. The indented area where the two bubbles are joined is the nose bridge 12B.

FIG 8

Fig 8 shows an alternate embodiment of a side view of top pleated bubble 32 with multiple, crown 40 and taper 43, pleats. Also shown are the pleat apexes 40A and pleat nadirs 40B, each denoting their respective high and low, or ridge and trough, portion of each pleat.

Unlike the unfilleted corners 70 of the Fig 7 embodiment, this Fig 8 embodiment has a corner fillet 72. Also note the apex 15A and nadir 15B. Bubble front 16 A is the front or proximal portion of bubble body 15 and bubble back 16B is the back or distal portion.

A Pleat Depth equals the difference in depth between pleat apex 40A and pleat nadir 40B. The Pleat Depth may be specified as 0.06, 0.1, 0.14, 0.18, 0.22, 0.25, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 inches. Variance on the above amounts may be specified as ± 0.02 or ± 0.05 inches.

Additionally, a Pleat Depth may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 0.1 inches, or less than 0.5 inches) and/or a range may be specified between any two of these disclosed amounts (such as between 0.06 and 0.25 inches).

Pleat width 45B, defined as the distance between the two adjacent pleat apexes 40A (or two adjacent pleat nadirs 40B, if more appropriate) of the same pleat, may be specified by the same numbers and ranges as the Pleat Depth, but specified independently of the Pleat Depth.

The inter-pleat distance 46, the distance between the centers of (or apexs) of adjacent Pleats, may also be specified by the same numbers and ranges as the Pleat Depth, but specified independently of the Pleat Depth.

The number of pleats 40 in the Fig 8 embodiment is six.

Flowever the number of pleats may be specified as one, two, three, four, five, six, seven, eight, nine, 10, 11, 12,

13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,

44, 45, 46, 47, 48, 49, and 50 pleats.

Additionally, the number of pleats may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 2, or less than 25 pleats) and/or a range may be specified between any two of these disclosed amounts (such as a range between 3 and 20 pleats).

This documents disclosures about pleats including the above and following provide a pleating means. The depth, width and number of pleats in the Fig 8 embodiment are calibrated to allow the vacuum formed film envelope of the pleated portion of bubble body 15 to bend 45° from a flat, Manufactured Configuration to the User Configuration without stretching the film envelope or collapsing portions of the bubble body 15. Vacuum Form Dimension Means: the depth, width and fillet dimensions of Fig 8 embodiment are calibrated to allow the vacuum forming of the plastic film to fully enter the vacuum form mold (or tool) and create all of the details of the shape layer 17. Fig 9

Fig 9 shows a top view of the Fig 8 embodiment. The crown area 15C, the portion of the bubble that contacts the user's face is quite visible, as are the corner fillets 72 and. crown pleats 40. The footprint of this embodiment also tapers visibly from its base apex 78A to its front base nadir 78B and rear base nadir 78C on either end.=====

Fig 10

Fig 10 is a perspective view of the Figure 8 embodiment and left top pleated bubble 32A, but also shows it paired with right top pleated bubble 32B. The space between them is nose gap 12 and the two bubble body 15s are seen with, i.e. on, their common flange 13.

Bubble Inflation

Bubble 10 formed with no greater or lesser air pressure than the ambient air around it can be considered 100% inflated. Greater than 100% inflation is positive air pressure, such as that inside an inflated balloon. Flowever, a bubble with less than 100% inflation may be desirable.

Because the bubble's envelope is flexible an underinflated bubble cannot be measured by air pressure, but must be measured by relative volume. Therefore, the percentage of bubble inflation is measured as the volume inside a bubble. For example, a 50% bubble inflation means the bubble's air volume is 50% compared to the maximum theoretical bubble volume (without pressure expansion or envelope stretching).

To improve the Bubble its ability to be deformed and accommodate, i.e. shape itself to, adjacent surfaces it may be desirable for the Bubble to be less than 100% inflated.

Bubble Inflation Range

A bubble inflation percentage may be specified as 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%,

45%, 40%, 35%, 30%, or 25%. Variance on the above amounts may be specified as ± 1% or ± 2.5%.

Additionally, the bubble inflation percentage may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 50%, or less than 95%) and/or a range may be specified between any two of these disclosed amounts (such as between 90% and 60%).

Bubble Deflation Means

Bubble Deflation Means: Bubble inflation may be reduced to less than 100% by a variety of methods. For example, the bubble may be sealed in a low pressure, i.e. partial vacuum environment, such that its air volume will be reduced when the Bubble is returned to standard air pressure.

Alternately, after shape layer 17 is formed, e.g. vacuum-formed, a portion of the mold that was used to form the film layer may be moved into the cavity to push into its surface and reduce the volume inside the cavity. Then base layer 18 is applied and the two layers are sealed together, finalizing the volume of bubble body 15.

Another method of reducing bubble inflation is to increase the size of the bubble after its molded rather than decrease the Bubble's volume. Figs 11 and 12 demonstrate a way to accomplish this is to is by placing a longitudinal inflation reduction ridge 100 ridge in the mold. This creates a reciprocal longitudinal inflation reduction pleat in the bubble. When the Bubble is removed the pleat opens, i.e. expands, perpendicularly and thereby increases the Bubble's surface area. This increases the Bubble cavity's volume (i.e. potential volume), but the volume of air is unchanged. Therefore the ratio between the two volumes has been altered and the degree of Bubble Inflation has been reduced.

Fig 11 shows top pleated bubble mold 90Awith no ridge 100X, while Fig 12 shows top pleated bubble mold 90B with the inflation reduction ridge 100. Fig 11 also shows expansion ridges 94 which mold the pleats into a bubble and the mold's vacuum hole 98. An arrow indicating longitudinal direction 102 is provided.

Note ridge 100 does not extend into the expansion ridge 94 portion of the mold, because the ridges would interfere with each other's functions.

Side Bubble Pleats

Figs 13 and 14 also show two otherwise identical side pleated bubble mold 92A and 92B except mold 92B has an inflation reduction ridge 100 oriented longitudinally to the bubble's length. This Ridge extends the full length possible within the cavity, such that it joins with the surface with each end of the cavity. Note that these side molds 92 are designed for a side pleated bubble 33 embodiment that is separate from the top pleated bubble 32.

Edge Pleats

The Figs 13 and 14 embodiments show molds for bubbles that have side pleats 42 on both sides. This may allow the bubble to bend more easily than just one set of side pleats, by providing room for compression.

Edge Pleats for Manufacturing

The edge pleat concept can be also applied to manufacturing the bubble and attaching it to the mask.

For example, if the top and side bubbles are continuous with each other, then manufacturing them will consume an unnecessary large, somewhat square, amount of film. Manufacturing the bubbles in a straight line (0°) then bend them at 90° to each other for mask attachment, consumes a smaller, more linear amount of plastic.

Utilizing edge pleats in the bubble connector 34 can provide a means to accomplish this.

In a similar manner, the manufacturing of any bubble or bubble subcomponent that can be 1) manufactured more efficiently in a straight line, 2) subsequently bent, and then 3) attach to a mask, may employ edge pleats (either on one side or both) to allow the bubble or subcomponent to bend into a desired geometry.

For example, the use of its pleats to assist in the manufacturing of bubbles for the full perimeter of a surgical mask or for curved perimeters such as cup-style masks including as N95 masks.

N95 MASK

Figs 15-18

Figs 15-18 disclose sealing means by which a bubble such as bubble 10 can be applied to an N95 mask or similar hemispherical or 3D-curved masks (pre-curved). Fig 15 shows a N95 mask 200 with its constituent parts: it's hemisphere 202 shape, a mask flange 204, a hemisphere perimeter 206 where hemisphere 202 and flange 204 meet, neck straps 208 and valve 219.

In this embodiment, attached about perimeter 206 is a partial perimeter bubble 210 with its constituent parts: a bubble tube 216, nose bubble 218, 12 top flange 13A, and bottom flange 13B. Weld attachments 214 provide a method of such tunnel bend. Top flange 13A is welded to mask flange 204 and bottom flange 13B is welded to the inside surface of hemisphere 202, such that bubble 210 straddles perimeter 206. Much of bubble 210 consists of bubble tube 216, but nose bubble 218 portions near nose gap 12 are larger to fill along the user's nose/cheek area.

Fig 16

Fig 16 shows a full perimeter bubble 212 similar to bubble 210 except it extends along the full perimeter of mask 200. The only perimeter 206 not covered with a portion of bubble is nose gap 12. The other notable difference is bubble 212 has a single, unified, bubble body 15 instead of the two separate body 15s of bubble 210. Fig 16 also shows section line B-B centered side to side on mask 200.

Bubble Coverage Means: The percentage of partial perimeter bubble 210 that extends around the hemisphere perimeter 206 may be specified as 20%, 25%, 30%, 35%, 40%, 45% 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, and 100%. Variance on the above amounts may be specified as ± 1% ± 2.5%, or ± 5%.

The percentage may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 25%, or less than 75 %) and/or a range may be specified between any two of these disclosed amounts (such as between 20% and 90%). If greater than 95% is specified in the partial perimeter bubble 210 has become a full perimeter bubble 212. If 100% is specified then bubble 212 has become a single continuous ring with no nose gap 12 (however the bubble body 15 diameter may vary, for instance to provide a larger nose bubble 218 relative to bubble tube 216).

Fig 17

Fig 17 shows a cross-section B-B of N95 mask 200. Its constituent parts include: hemisphere 202, mask flange 204, and hemisphere perimeter 206. Neck straps 208 and valve 219 are not shown.

Fig 17 shows a cross-section B-B of N95 mask 200. Its constituent parts include: hemisphere 202, mask flange 204, and hemisphere perimeter 206. Neck straps 208 and valve 219 are not shown.

Disclosed is a flange bubble 240 with its constituent parts: bubble tube 216, nose bubble 218 (collectively bubble body 15), and outer flange 13A. To specify the relevant geometry centerline 230, path radius 232, and flange adjacency 234 are provided. Path radius 232 is the radial distance between centerline 230 and the center of bubble tube 216. The flange adjacency 234 distance is between the center of tube 216 and hemisphere perimeter 206.

In Fig 17, the bubble body 15 including tube 216 is adjacent to hemisphere perimeter 206. In Fig 18 it is not adjacent. Here, the bubble 15 is spaced at a flange adjacency 234 distance from perimeter 206. This provides a fit adjustment means whereby bubble 212 is held in suspension in roughly the same plane as mask flange 204, but can flex down and into the hemisphere 206 when mask 200 is placed on the user's face such that it fits the user's face. That is to say, if a person has a small face, floating bubble 250 will remain closer to its original position and not flex or stretch much, i.e. it will retain a similar path radius 232. To accommodate a larger face the floating bubble 250 will flex and and/or stretch increasing the path radius 232.

Note, bubbles 240 and 250 have only only one flange 13A. There is no flange 13B. Flange 13A attaches to mask flange 204. This simplifies manufacturing.

Dimensional Fiting Means: The flange adjacency 234 dimension of floating bubble 250 may be specified as 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 and 1.0 inches. Specified as zero, bubble 250 becomes flange bubble 240. Variance on the above amounts may be specified as ± 1%, ± 2.5%, or ± 5%.

The flange adjacency 234 dimension may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 0.2, or less than 0.6 inches) and/or a range may be specified between any two of these disclosed amounts (such as between 0.1 and 0.5).

ELASTIC CHIN CORD

The following disclosure is an elastic cord means of improving surgical masks such that have a much superior seal and also can accommodate a very large range of face sizes and shapes with a single mask size/configuration.

Tunnel Cord Means

Fig 19 shows mask 301 and its body 302. body 302 typically made from three constituent parts: an outer layer 2A, a mid layer 2B, and an inner layer 2C. Also shown is a single cord 310 which replaces the typical two ear loops 7. Cord 310 is attached at the upper mask 301 corners in approximately the same area, and by the same manufacturing method, as ear loops 7. Cord 310, however, is not attached directly to the lower corners of mask 301, instead it passes through the layers of mask 301 and is slidably constrained there by mask welds 330.

Mask welds 330, similar to the typical welds used to construct a typical surgical mask, are employed on both sides of cord 310 to create a cord tunnel 312 between outer layer 2A and mid layer 2B. While the tunnel 312 could be a simple straight line through the mask, in this embodiment it angles up near the mask's lower corners such that the cord 310 exits closer towards the middle of the side of the mask. Two inside radius points control and define the tunnel 312's angle geometry: tunnel bend A 316 and tunnel bend C 318. More on this will be covered later.

Figure 20 shows a method of manufacturing the cord tunnel 312. First mask welds 332 are placed on body 302 along the top and part of the side in the same fashion as would be typical for a typical surgical mask. This includes providing a pocket for a nose wire 9. The difference is welds 332 along the bottom not extend all the way to the bottom of body 302 and welds 332 do not fill into the lower corners. Cord 310 may be placed into the open flap after the placement of welds 332, but alternatively may be put in place before welding.

Fig 21 - The next manufacturing step, as disclosed in Fig 21 is to place second mask welds 334 along the bottom of body 302 and throughout the two lower corners of body 302. This finalizes the construction of cord tunnel 312, while also defining tunnel bend A 316, which controls and defines the exit point for cord 310.

Each end of cord 310 is welded with a cord weld 336 to the upper corners of body 302 to create ear loops. Cord weld 336 can be performed simultaneously to second mask weld 334, or optionally welded subsequently. Fig 22 discloses A mask 401 and a body 402 and an alternate method of manufacturing cord tunnel 312. In order to control the position of cord 310 while making the long thin portion of tunnel 312 along the bottom of mask 301, cord 310 may be pulled taut in a horizontal direction 320 on either side of mask 301 so that it forms into a straight line.

First mask welds 332, shown as dashed lines, are placed on other side of cord 310 along this bottom portion of the mask 301, creating tunnel 312 along this area. However, the angled area, beyond tunnel bend C 318 and tunnel bend B 317, has first mask welds 332 on only one side (inside part of tunnel), as shown.

Fig 2323 shows the cord 310 moved into its final configuration and being confined by second mask welds 334. This completes the cord tunnel 312 and creates and defines attachment A 316.

Measured from the lower corner(s) of body 402, the tunnel bend C 318 location is specified by horizontal dimension 340 and vertical dimension 348, tunnel bend B 317 location is specified by horizontal dimension 342 and vertical dimension 346, and tunnel bend A 316 location is specified by vertical dimension 344. Tunnel bend A 316 generally does not require horizontal dimension because it's adjacent to the edge of body 402.

Dimensional Vector Means: as a means of controlling the angle and/or resulting elastic pull vector of at least one of the horizontal or vertical dimensions 340 through 348, one or more of them may be specified as 0, 0.1 , 0.2, 0.3,

0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or

3.0 inches. Variance on the above amounts may be specified as ± 0.01, ± 0.025, or ± 0.04 inches.

Alternatively, the horizontal or vertical dimensions may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 0.2, or less than 2.5 inches) and/or a range may be specified between any two of these disclosed amounts (such as between .5 and 2.0). To clarify, each of the dimensions 340 through 348 may be specified by the Dimensional Vector method above, independently of each other. For example, dimension 340 may be specified as 1.0 inches, dimension 342 as 0.2 inches, and dimension 344 as 2.0 inches.

Tunnel bends A 316, B 317, and C 318 are specified as the positions at which straight lines change angles. However, the intersections of the straight lines can be filleted and the fillets can even be large enough to obscure the straight lines and become tangent arcs.

Intersection Filleting Means: intersection fillets may be specified as is having a radius of 0.1, 0.2, 0.3, 0.4, 0.5,

0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0 inches. Variance on the above amounts may be specified as ± 0.01, ± 0.025, or ± 0.04 inches.

Alternatively, the intersection fillets may be specified as greater than, or less than, any one of these disclosed amounts (such as greater than 0.1, or less than 1.0 inches) and/or a range may be specified between any two of these disclosed amounts (such as between .2 and 1.2).

Organic, parabolic or complex curves curves with approximately equivalent functionality may be considered equivalent and specified by the above Intersection Filleting Means. To use mask 401, the user pulls cord 310 away from the portion of the mask that it exits from to crumple the portion of the mask that cord 310 tunnels through, primarily the bottom of the mask. The crumpling is analogous to drawing curtains open which crumple the curtain material on the curtain rod.

Because the elastic cord 310 is also the ear loops 7, when the mask is worn the ear loop portion pulls tension on the elastic cord and through the bottom of the mask. This tightens and fits the mask against the users chin. Simultaneously, the tension on the bottom of the mask pulls the sides of a mask flat against the user's face, instead of allowing the problematic gaping along the sides a mask with traditional masks. The result is a versatile and effective seal on the sides and bottom of mask 401. Accordingly, embodiments without side bubbles are viable.

Another advantage of the mask 401 is because cord 310 is elastic, it allows the mask to dynamically stretch and rebound, thereby accommodating the opening and closing of the user's jaw. Such resilient jaw movement accommodation maintains a superior mask seal when a person is talking or chewing.

Combination Means

As stated, mask 401 provides an effective seal on the sides and bottom of the mask without impacting the seal on the top of the mask. Therefore an embodiment, or embodiments, is disclosed that combines the bubble designs and concepts with the unitary elastic cord 310 that passes through a cord tunnel 312 designs and concepts. For example adding the Fig 10 bubble embodiment to the mask 401 embodiment.

The addition of the bubble to seal the top of the mask combined with the tunnel cord design creates a mask with a highly effective seal on all four sides, to reduce or eliminate mask leakage. This combination produces a highly effective, yet inexpensive and manufacturable improvement on the standard surgical mask.

Non-Surgical Masks - One or several of the design concepts herein disclosed for the mask 401 may be applied to non-surgical masks, and in particular to non-disposable cloth masks.

Disclosure Crossover

Any design, embodiment or disclosure made in this application may be selected to be combined with, applied to, and/or adapted to any other design, embodiment or disclosure of this application or to existing or known mask designs or disclosures.

For example, the full perimeter seal disclosed for the N95 mask may be applied to the surgical mask disclosures in this application to disclose a full perimeter seal for surgical masks, or a full perimeter seal for existing disposable respirator masks such as KF-94 masks, for reusable cloth masks, or for nondisposable masks.

Conclusion

The disclosed designs can improve the protection afforded by disposable air filtration masks by improving the seal between the mask and the users face, and to do so in a cost-effective manner. Additionally, some of the disclosed embodiments are designed to minimize eyeglass fogging, improve fit versatility, and improve user comfort.