Facemask and Method of Manufacturing Same

FIELD OF THE INVENTION

The present invention relates generally to the field of protective facemasks, and more specifically to a facemask without a metal nose wire and a manufacturing process for such facemasks. BACKGROUND OF THE INVENTION

Various configurations of disposable filtering facemasks or respirators are known and may be referred to by various names, including "facemasks",

"respirators", "filtering face respirators", and so forth. For purposes of this disclosure, such devices are referred to generically as "facemasks."

The ability to supply aid workers, rescue personnel, and the general populace with protective facemasks during times of natural disasters or other catastrophic events is crucial. For example, in the event of a pandemic, the use of facemasks that offer filtered breathing is a key aspect of the response and recovery to such event. For this reason, governments and other municipalities generally maintain a ready stockpile of the facemasks for immediate emergency use. However, the facemasks have a defined shelf life, and the stockpile must be continuously monitored for expiration and replenishing. This is an extremely expensive undertaking.

Recently, investigation has been initiated into whether or not it would be feasible to mass produce facemasks on an "as needed" basis during pandemics or other disasters instead of relying on stockpiles. For example, in 2013, the

Biomedical Advanced Research and Development Authority (BARDA) within the Office of the Assistant Secretary for Preparedness and Response in the U.S.

Department of Health and Human Services estimated that up to 100 million facemasks would be needed during a pandemic situation in the U.S., and proposed research into whether this demand could be met by mass production of from 1.5 to 2 million facemasks per day to avoid stockpiling. This translates to about 1 ,500 masks/minute. Current facemask production lines are capable of producing only about 100 masks/minute due to current technology and equipment restraints, which falls far short of the estimated goal. Accordingly, advancements in the manufacturing and production processes will be needed if the goal of "on demand" facemasks during a pandemic is to become a reality.

The various configurations of filtration facemasks include a flexible, malleable metal piece, known as "nose wire", along the edge of the upper filtration panel to help conform the facemask to the user's nose and retain the facemask in place during use, as is well known. The nose wire may have a varying length and width between different sizes and mask configurations, but is generally cut from a spool in a continuous in-line process cutting and crimping process and then laid directly onto a running carrier nonwoven web (which may include a plurality of nonwoven layers) along an edge that becomes a top edge of the finished mask. The edge is subsequently sealed with a binder material, which also encapsulates and

permanently holds the nose wire in place at the top edge. Transport and placement of the individual nose wires from the cutting/crimping station onto the carrier web must be precise to ensure the correct location of the nose wires in the finished face masks. For mass production of facemasks at the throughputs mentioned above, the production rates (throughput) of the individual nose wires from the cutting/crimping station and transport speed of the carrier web will necessarily be significantly higher as compared to conventional manufacturing lines.

Attachment of the nose wires contributes to much of the time and complexity of current facemask production. In addition, the nose wires of individual facemasks are difficult to recycle as they are metal and embedded into the nonwoven layers of the facemask.

Accordingly, the present invention addresses the aforementioned issues and provides a facemask without a nose wire that can be manufactured at the desired throughputs required during a pandemic as explained herein.

SUMMARY OF THE INVENTION

Objects and advantages of the invention will be set forth in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one aspect, the present disclosure is directed to a protective facemask absent of a nose wire. Such a facemask generally includes a body having a top edge and a bottom edge that cooperate with each other to define a periphery that contacts a wearer's face. Further, the top edge includes a treated zone containing a surface coating. The surface coating contains a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face. More specifically, in one embodiment, the non-metal malleable material may include a polymeric material or a high molecular weight alcohol. For example, in certain embodiments, the polymeric material may include cyanoacrylates, lightweight polyester thermoplastics, silicones (e.g. polydimethyl siloxane or room temperature curable silicone) or similar. In addition, the non-metal malleable material may include a water-based moldable modeling dough, a paraffin wax blended with a softener or plasticizer (such as petroleum jelly), or similar.

In another embodiment, the surface coating may be applied to the top edge in a substantially thin-strip configuration. For example, in one embodiment, the thin- strip configuration may have a generally rectangular cross-section. Further, the surface coating may be located in a substantially centered location along a length of top edge.

The body of the facemask may have any suitable configuration. For example, in one embodiment, the body may have a duck-bill configuration with an upper portion and a lower portion secured together along one or more sides thereof. More specifically, in such an embodiment, the upper and lower portions of the body may be bonded together via at least one of heat or ultrasonic sealing along three sides. Further, at least one of the sides of the facemask may be left open. Thus, the open side of the top and bottom edges may cooperate with each other to define the periphery that contacts the wearer's face. In addition, the upper and lower portions of the body may have complimentary shapes, including for example, complimentary trapezoidal or rectangular shapes.

In alternative embodiments, the body may have a layered configuration having a generally rectangular shape that covers the nose and mouth of the wearer's face.

In additional embodiments, the body may be constructed, at least in part, of an air-permeable material. Alternatively, the body may be constructed, at least in part, of a non-permeable material.

In further embodiments, the facemask may include one or more securing members configured to secure the body of the facemask to the wearer's face. More specifically, in certain embodiments, the securing member(s) may be elastic straps, adjustable straps, or similar. In another aspect, the present disclosure is directed to a method of manufacturing a protective facemask. More specifically, the method includes forming a filter body of the facemask having a top edge and a bottom edge. Further, the top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. The method also includes applying a surface coating to at least a portion of the top edge. The surface coating includes a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face. It should also be understood that the method may further include any of the additional steps and/or features as described herein.

In one embodiment, the step of forming the filter body may include providing an upper portion and a lower portion of a filter body of the facemask. Thus, in such an embodiment, the method may include securing the upper and lower portions of the filter body along one or more sides thereof while leaving at least one of the sides of the facemask open, e.g. via at least one of heat or ultrasonic sealing. As such, the open side defines a top edge and a bottom edge that cooperate with each other to define a periphery that contacts a wearer's face.

In additional embodiments, the method may also include applying the surface coating to at least a portion of the top edge so as to form a thin-strip configuration. In further embodiments, the method may include attaching one or more securing members to the filter body, the securing members configured to secure the facemask to the wearer's face.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which: FIG. 1 illustrates a perspective view of a conventional respiratory facemask worn by a user, the facemask incorporating a nose wire to conform the facemask to the user's face;

FIG. 2 illustrates a top view of the conventional facemask of FIG. 1 is a folded state;

FIG. 3 illustrates a top view of the conventional facemask of FIG. 1 , particularly illustrating a portion of the nose wire exposed;

FIG. 4 illustrates a cross-sectional view of the facemask of FIG. 2 taken along line 2-2;

FIG. 5 illustrates a top view of the one embodiment of a facemask according to the present disclosure, particularly illustrating a treated zone applied to the top edge thereof;

FIG. 6 illustrates a cross-sectional view of the facemask of FIG. 5 taken along line 5-5; and

FIG. 7 illustrates a flow diagram of one embodiment of a method for manufacturing a facemask according to the present disclosure.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

Reference now will be made in detail to various embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, may be used on another embodiment to yield a still further

embodiment. Thus, it is intended that the present invention covers such

modifications and variations as come within the scope of the appended claims and their equivalents.

Generally, the present disclosure is directed to a protective facemask absent of a nose wire that can be used in multiple applications, such as in the medical field or during a pandemic. For example, the facemask protective includes a body having a top edge and a bottom edge. The top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. Further, the top edge includes a treated zone containing a surface coating. More specifically, the surface coating contains a non-metal malleable material (e.g. a polymeric material or a high molecular weight alcohol) that can be manipulated so as to retain a shape that fits contours of the wearer's face.

Thus, the surface coating replaces the nose wire of conventional facemasks and provides many advantages not present in the prior art. For example, the polymeric material can be carefully chosen such that the final coating is safe for human skin contact while also remaining flexible and conformable. As such, the surface coating allows a user to manipulate the treated zone to take a shape of his or her nose such that the facemask remains secure during use. In addition, the surface coating can be applied at high-speeds, thereby reducing manufacturing time and costs. Further, as the present facemasks do not contain metal, such facemasks can be easily recycled.

Various styles and configurations of conventional facemasks are well known, including flat pleated facemasks and duck-bill facemasks. For illustrative purposes only, aspects of the present facemasks and methods are described herein with reference to a particular type of respirator facemask often referred to in the art as a "duckbill" mask, as illustrated in FIG. 1.

Referring to FIGS. 1-4, a conventional facemask 1 1 (e.g., a duckbill facemask) having a nose wire 26 is illustrated on the face of wearer 12. As generally shown, the mask 11 includes filter body 14 that is secured to the wearer 12 by means of resilient and elastic straps or securing members 16 and 18. The filter body 14 includes an upper portion 20 and a lower portion 22, both of which have complimentary trapezoidal shapes and are preferably bonded together such as by heat and/or ultrasonic sealing along three sides. Bonding in this manner adds important structural integrity to mask 1 1.

The fourth side of the mask 1 1 is open and includes a top edge 24 and a bottom edge 38, which cooperate with each other to define the periphery of the mask 1 1 that contacts the wearer's face. The top edge 24 is arranged to receive an elongated malleable member 26 (FIGS. 2-4) in the form of a flat metal ribbon or wire (referred to herein as a "nose wire"). FIG. 3 illustrates the nose wire 26 partially exposed and partially embedded in the facemask 1 1. As is generally understood, the nose wire 26 is provided so that the top edge 24 of the mask 11 can be configured to closely fit the contours of the nose and cheeks of wearer 12. Further, the nose wire 26 is typically constructed from an aluminum strip with a rectangular cross-section. With the exception of having the nose wire 26 located along top edge 24 of the upper portion 20 of the mask 11 , the upper and lower portions 20 and 22 may be identical.

As shown in FIG. 1 , the mask 1 1 has the general shape of a cup or cone when placed on the face of wearer 12 and thus provides "off-the-face" benefits of a molded-cone style mask while still being easy for wearer 12 to carry mask 1 1 in a pocket prior to use. "Off-the-face" style.masks provide a larger breathing chamber as compared to soft, pleated masks which contact a substantial portion of the wearer's face. Therefore, "off-the-face" masks permit cooler and easier breathing.

Blow-by associated with normal breathing of the wearer 12 is substantially eliminated by properly selecting the dimension and location of the nose wire 26 with respect to top edge of 24. The nose wire 26 is preferably positioned in the center of top edge 24 and has a length in the range of fifty percent (50%) to seventy percent (70%) of the total length of the top edge 24.

As illustrated in cross-sectional view of FIG. 4, the upper and lower portions

20 and 22 of the mask 11 may include multiple layers each having an outer mask layer 30 and inner mask layer 32. Located between the outer and inner mask layers 30, 32 are one or more intermediate filtration layers 34. This intermediate layer 34 is typically constructed from a melt-blown polypropylene, extruded polycarbonate, melt-blown polyester, or a melt-blown urethane.

In addition, the top edge 24 of the mask 1 1 is faced with an edge binder 36 that extends across the open end of mask 11 and covers the nose wire 26.

Similarly, the bottom edge 38 is encompassed by an edge binder 40. The edge binders 36 and 40 are folded over and bonded to the respective edges 24, 30 after placement of the nose wire 26 along the top edge 24. The edge binders 36, 40 may be constructed from a spun-laced polyester material.

As mentioned, however, attachment of the nose wires (such as the nose wire 26 described in reference to FIGS. 104) contributes to much of the time and complexity of current facemask production. In addition, conventional facemasks 11 can be difficult to recycle due to the embedded metal nose wires 26. Thus, the present disclosure is directed to an improved facemask 100 that does not include a nose wire.

For example, as shown in FIGS. 5 and 6, a facemask 100 according to one embodiment of the present disclosure is illustrated. More specifically, as shown, the facemask 100 of the present disclosure includes a treated zone 106 containing a surface coating 08 rather than having a nose wire 26 as discussed in regards to FIGS. 1 -4. Further, as shown, the mask 100 includes body 1 14 that is secured to the wearer by means of resilient and/or elastic straps (e.g. such as the securing members 16, 18 shown in FIG. 2). Moreover, as shown in FIG. 6, the body 114 may include an upper portion 120 and a lower portion 122, both of which have

complimentary trapezoidal shapes and are preferably bonded together. Thus, as shown, the fourth side of the mask 100 is open and includes a top edge 124 and a bottom edge 138, which cooperate with each other to define the periphery of the mask 100 that contacts the wearer's face.

Though the facemask 100 is illustrated as having a "duckbill" configuration, it should be understood that any suitable facemask configuration is suitable for the surface coating as described herein. More specifically, as shown, the top edge 124 is arranged to receive the surface coating 108 in the form of a thin-strip

configuration. For example, in one embodiment, the thin-strip configuration may have a generally rectangular cross-section. Further, the surface coating 108 contains a non-metal malleable material that can be manipulated by a user so as to retain a shape that contours with a wearer's face. More specifically, in one embodiment, the non-metal malleable material may be a polymeric material or a high molecular weight alcohol. For example, in certain embodiments, the polymeric material may include cyanoacrylates, lightweight polyester thermoplastics, silicones (e.g. polydimethyl siloxane or room temperature curable silicone) or similar.

Further, the high molecular weight alcohols may include any suitable wax or waxlike material. In addition, the high molecular weight alcohols may include any suitable sticky and/or malleable substance. In addition, the non-metal malleable material may include a water-based moldable modeling dough such as described in U.S. Patent Number 7,897,659 entitled "Water-based moldable modeling dough and method preparing therefor" filed on January 23, 2009 which is incorporated herein by reference in its entirety. Further, the non-metal malleable material may include paraffin wax blended with a softener or plasticizer (such as petroleum jelly) or similar.

Thus, the surface coating 108 is provided so that the top edge 124 of the mask 100 can be configured to closely fit the contours of the nose and cheeks of wearer 12. Further, the polymeric material may be chosen such that the final coating is safe for human skin contact while also remaining flexible and

conformable. Thus, in such embodiments, the edge binders may be eliminated so as to further reduce production time for the facemasks. In alternative embodiments, the non-metal malleable material may be applied between the edge binders.

As illustrated in cross-sectional view of FIG. 6, the upper and lower portions

120 and 122 of the mask 100 may be configured similar to that of the mask 11 of FIG. 4. Thus, the present facemask 100 may include multiple layers each having an outer mask layer 30 and inner mask layer 32. Located between the outer and inner mask layers 130, 132 are one or more intermediate filtration layers 134. Further, as mentioned, the intermediate layer(s) 134 may be constructed from a melt-blown polypropylene, extruded polycarbonate, melt-blown polyester, or a melt-blown urethane. In addition, the upper and lower portions 120, 122 of the body 114 may have complimentary shapes, including but not limited to complimentary trapezoidal shapes (as shown), complimentary rectangular shapes (as generally known in the art), or any other suitable shape.

In additional embodiments, the body 114 of the facemask 100 may be constructed of an air-permeable material. In such embodiments, the body 1 14 is configured to allow the free passage of air but prevent the permeation of germs therethrough. Such materials are particularly useful for constructing facemasks that can be used during pandemics.

Referring now to FIG. 7, a flow diagram of one embodiment of a method 200 of manufacturing a facemask 100 according to the present disclosure is illustrated. As shown at 202, the method 200 includes forming a filter body of the facemask having a top edge and a bottom edge. As such, the top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. For example, in certain embodiments, the body of the facemask may be a single- or multi-layered non-woven web having a generally rectangular or square shape. In addition, as generally shown in the figures, the method 200 may include forming the body 1 14 of the facemask 100 from an upper portion 120 and a lower portion 122. More specifically, in certain embodiments, the method 200 includes securing the upper and lower portions 120, 122 of the filter body 1 14 along one or more sides thereof while leaving at least one of the sides of the facemask open. Thus, the open side defines a top edge 124 and a bottom edge 138 that cooperate with each other to define a periphery that contacts a wearer's face. As shown at 204, the method 200 also includes applying a surface coating 108 to at least a portion of the top edge 124. More specifically, the step of applying the surface coating 108 to the top edge 124 may include dispensing, dispersing, or printing the surface coating 108 onto the top edge 124 of the facemask. Thus, the surface coating 108 can be any suitable material that can be applied to the top edge 124 using the techniques as described herein. Further, in another embodiment, as shown in FIG. 5, the method 200 may include applying the surface coating 108 to at least a portion of the top edge 124 so as to form a thin-strip configuration. For example, as shown, the surface coating 108 may be applied substantially in the center of top edge 124 and may have a length in the range of fifty percent (50%) to seventy percent (70%) of the total length of the top edge 124.

As mentioned, the surface coating 108 that is applied to the top edge 124 of the facemask includes a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face. More specifically, the non-metal malleable material may include a polymeric material or a high molecular weight alcohol such as those described herein.

In further embodiments, the method 200 may include attaching one or more securing members (e.g. elastic or adjustable straps) to the filter body 114. Thus, the securing members are configured to secure the facemask 100 to the wearer's face.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any

incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.