CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

REFERENCE TO A MICROFICHE APPENDIX [0003] Not applicable.

BACKGROUND

[0004] Personal protection equipment (PPE), specifically disposable masks, may be designed considering the convenience of the user wearing the mask, as well as the filtration properties of the mask. The user's ability to and ease of breathing while wearing the mask may be considered, as well as the fit and the comfort of the user who may wear the mask. Because of the disposable nature of the mask, a low cost manufacturing process may be desired. Additionally, masks may be foldable to provide convenience when a user may wish to carry the mask. Filtration by a mask is accomplished when particles in the air are trapped in the matrix of the fibers contained in the filtration media of the mask.

SUMMARY

[0005] Aspects of the disclosure may include embodiments of a foldable, disposable mask, comprising: a mask shape comprising: a pentagon portion having a lower triangular shape and an upper quadrilateral shape, a first and second quadrilateral portion, wherein the first and second quadrilateral portions are proximate to the lower triangular portion of the pentagon portion at a first crease and a second crease; a first trilateral portion positioned between the first and second quadrilateral portions proximate to the lower triangular shape of the pentagon portion; a second and third trilateral portion proximate to the upper quadrilateral shape of the pentagon portion and the first quadrilateral portion, wherein the first quadrilateral portion and the second trilateral portion meet at a third crease, the pentagon portion and the third trilateral portion meet at a fourth crease, and the second trilateral portion and the third trilateral portion meet at a fifth crease; a fourth and fifth trilateral portion proximate to the upper quadrilateral shape of the pentagon portion and the second quadrilateral portion, wherein the second quadrilateral portion and the fourth trilateral portion meet at a sixth crease, the pentagon portion and the fifth trilateral portion meet at a seventh crease, and the fourth trilateral portion and the fifth trilateral portion meet at an eighth crease.

[0006] In some embodiments, the mask shape is operable to be folded into one of three shapes, wherein the shapes comprise: a first shape formed by folding the first trilateral portion along a ninth crease, nipping the first quadrilateral portion and the second quadrilateral portion together along a tenth crease and an eleventh crease, and folding the quadrilateral portion approximately in half along a twelfth crease; or a second shape formed by folding the second trilateral portion, the first quadrilateral portion, and the first trilateral portion backward along creases, and folding the fourth trilateral portion and the second quadrilateral portion backward along creases; or a third shape formed by forming the second shape as described, folding the second trilateral portion and the third trilateral portion inwards along a crease, and folding the fourth trilateral portion and the a fifth trilateral portion inwards along crease.

[0007] Additional aspects of the disclosure may include embodiments of a method of folding a disposable mask, comprising: providing a mask shape formed from a nonwoven fabric material, wherein the mask shape comprises a plurality of creases and cut-outs; folding the mask shape via the creases to align the edges of the cut-outs; securing the edges of the mask shape proximate the cut-outs; and folding portions of the mask shape to form a folded mask shape, wherein securing the edges of the cut-outs creates a three-dimensional mask shape from the flat nonwoven fabric material that fits about the face of a user, and the folded mask shape is operable to be repeatedly unfolded and folded via the creases of the mask shape. [0008] In some embodiments, the steps of folding and securing further comprise: folding a first portion of the mask onto a second portion of the mask along a first crease to align the edges of a first cut-out; securing the fabric along the edges of the first cut-out; folding a third portion of the mask onto the second portion of the mask along a second crease to align the edges of a second cut-out, wherein the first and third portions of the mask meet to form a fourth and fifth portion of the mask, and wherein the fourth and fifth portions meet at the edges of a third cut-out; securing the fabric along the edges of the second cut-out; folding the fourth and fifth portions of the mask along a third crease onto the first portion of the mask; securing the fabric along the edges of the third cut-out; and folding the third portion of the mask onto the fourth portion of the mask, wherein the second portion of the mask is folded in half. In some embodiments, the method may further comprise attaching nose clips, head straps, and other appendages to the folded mask, and packaging the folded mask. In some embodiments, a plurality of folded masks may be formed and packaged together in a group. In some embodiments, securing comprises ultrasonic welding or heat melting of the nonwoven fabric. In some embodiments, the method may further comprise providing or stamping creases into the nonwoven fabric material by a roller. In some embodiments, the steps of the method may be completed manually. In some embodiments, the steps of the method may be completed automatically.

[0009] Additional aspects of the disclosure may include embodiments of a method of folding a disposable mask, comprising: providing a mask shape formed from a nonwoven fabric material, wherein the mask shape comprises a plurality of creases; folding a first portion of the mask shape along a first set of creases, wherein the first portion lays behind a second portion of the mask shape; and folding a third portion of the mask shape along a second set of creases, wherein the third portion of the mask shape lays behind the second potion of the mask shape and behind the first portion of the mask shape, wherein: the mask shape comprises a three-dimensional mask shape that fits about the face of a user, and the mask shape is operable to be repeatedly unfolded and folded via the creases of the mask shape. [0010] In some embodiments, the method may further comprise folding a fourth portion of the mask along a third set of creases, wherein the fourth portion lays between the first and second portions of the mask; and folding a fifth portion of the mask along a fourth set creases, wherein the fifth portion lays between the second and third portions of the mask. In some embodiments, the method may further comprise attaching nose clips, head straps, and other appendages to the folded mask; and packaging the folded mask. In some embodiments, the method may further comprise molding a flat nonwoven fabric material to form the three-dimensional mask shape and creases, wherein molding comprises pressing the nonwoven fabric material between an upper mold and a lower mold. In some embodiments, the method may further comprise cutting excessive fabric from the nonwoven fabric material, wherein molding and cutting may be completed simultaneously. In some embodiments, the steps of the method may be completed manually. In some embodiments, the steps of the method may be completed automatically.

[0011] Other aspects of the disclosure may include embodiments of a disposable, foldable mask, comprising: a three-dimensional mask shape that covers the nose and mouth of the user that, when folded, comprises: at least five creases; a total height of no more than approximately 150 millimeters; and a total width of no more than approximately 180 millimeters, wherein the mask shape is formed from a nonwoven fabric material having cut-outs; and a plurality of creases on the mask shape operable to be folded to align the edges of the cut-outs to form a folded mask shape, wherein the edges of the cut-outs are secured to facilitate folding and unfolding of the mask shape multiple times via the creases.

[0012] In some embodiments, the cut-outs comprise at least three cut-outs. In some embodiments, the cut-outs are positioned symmetrically about a central axis of the mask shape. In some embodiments, the edges of the cut-outs are secured using ultrasonic welding. In some embodiments, the mask shape may comprise a plurality of portions defined by the creases and cut-outs. [0013] Aspects of the disclosure may include embodiments of a method of manufacturing a personal protection equipment mask, comprising: providing a flat nonwoven fabric material; providing or punching creases into the nonwoven fabric material to form a mask shape; cutting excessive fabric from nonwoven fabric material, wherein cutting creates cut-outs into the mask shape; folding the mask shape via the creases to align the edges of the cut-outs; welding the edges of the fabric at the cut-outs; and folding portions of the mask shape to form a folded mask shape, wherein welding the edges of the cut-outs creates a three-dimensional mask shape from the flat nonwoven fabric material that fits about the face of a user, and the folded mask shape is operable to be repeatedly unfolded and folded via the creases of the mask shape.

[0014] In some embodiments, the steps of folding and welding further comprise: folding a first portion of the mask onto a second portion of the mask along a first crease to align the edges of a first cut-out; welding along the edges of the first cut-out; folding a third portion of the mask onto the second portion of the mask along a second crease to align the edges of a second cut-out, wherein the first and third portions of the mask meet to form a fourth and fifth portion of the mask, and wherein the fourth and fifth portions meet at the edges of a third cut-out; welding along the edges of the second cut-out; folding the fourth and fifth portions of the mask along a third crease onto the first portion of the mask; welding along the edges of the third cut-out; and folding the third portion of the mask onto the fourth portion of the mask, wherein the second portion of the mask is folded in half. In some embodiments, the method may further comprise attaching nose clips, head straps, and other appendages to the folded mask, and packaging the folded mask. In some embodiments, a plurality of folded masks may be formed and packaged together in a group. In some embodiments, welding comprises ultrasonic welding of the nonwoven fabric. In some embodiments, providing or punching creases into the nonwoven fabric material is completed automatically by a roller.

[0015] Additional aspects of the disclosure may include embodiments of a method of manufacturing a disposable, foldable mask, comprising: providing a flat nonwoven fabric material; molding the nonwoven fabric material to form a mask shape, wherein the mask shape comprises a plurality of creases; cutting excessive fabric from nonwoven fabric material; folding a first portion of the mask along a first set of creases, wherein the first portion lays behind a second portion of the mask; and folding a third portion of the mask shape along a second set of creases, wherein the third portion of the mask shape lays behind the second potion of the mask and behind the first portion of the mask shape, wherein: molding creates a three-dimensional mask shape from the flat nonwoven fabric material that fits about the face of a user, and the mask shape is operable to be repeatedly unfolded and folded via the creases of the mask shape.

[0016] In some embodiments, the method may further comprise folding a fourth portion of the mask along a third set of creases, wherein the fourth portion lays between the first and second portions of the mask; and folding a fifth portion of the mask along a fourth set creases, wherein the fifth portion lays between the second and third portions of the mask. In some embodiments, the method may further comprise attaching nose clips, head straps, and other appendages to the folded mask; and packaging the folded mask. In some embodiments, the steps of molding and cutting are completed simultaneously. In some embodiments, molding comprises pressing the flat nonwoven fabric material between an upper mold and a lower mold.

[0017] Other aspects of the disclosure may include embodiments of a method of manufacturing a disposable, foldable mask, comprising: providing a flat nonwoven fabric material; providing or punching creases into the nonwoven fabric material to form a mask shape; cutting excessive fabric from nonwoven fabric material, wherein cutting creates cut-outs into the mask shape; folding a first portion of the mask onto a second portion of the mask along a first crease to align the edges of a first cut-out; welding along the edges of the first cut-out; folding a third portion of the mask onto the second portion of the mask along a second crease to align the edges of a second cut-out, wherein the first and second portions of the mask meet to form a fourth and fifth portion of the mask, and wherein the fourth and fifth portions meet at the edges of a third cut-out; welding along the edges of the second cut-out; folding the fourth and fifth portions of the mask along a third crease onto the first portion of the mask; welding along the edges of the third cut-out; and folding the third portion of the mask onto the fourth portion of the mask, wherein the second portion of the mask is folded in half, thereby forming a folded mask shape.

[0018] In some embodiments, the method may further comprise forming a plurality of foldable masks by repeating the steps of the method. In some embodiments, the method may further comprise packaging the plurality of foldable masks together. In some embodiments, the steps of folding and welding form a three-dimensional mask shape that fits about the face of a user.

[0019] These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0021] FIGS. 1A-1D illustrate exemplary embodiments of a foldable mask;

[0022] FIGS. 2A-2C illustrate steps of a method for manufacturing a foldable mask;

[0023] FIGS. 3A-3G illustrate further steps of a method for manufacturing a foldable mask;

[0024] FIG. 4 illustrates a exemplary embodiment of a folded mask shape;

[0025] FIGS. 5A-5D illustrate steps of another method for manufacturing foldable masks;

[0026] FIGS. 6A-6D illustrate further steps of another method for manufacturing a foldable mask;

[0027] FIGS. 7A-7D illustrate still further steps of another method for manufacturing a foldable mask; and

[0028] FIG. 8 illustrates an exemplary embodiment of a folded mask shape.

DETAILED DESCRIPTION [0029] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

[0030] The following brief definition of terms shall apply throughout the application:

[0031] The term "comprising" means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

[0032] The phrases "in one embodiment," "according to one embodiment," and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);

[0033] If the specification describes something as "exemplary" or an "example," it should be understood that refers to a non-exclusive example;

[0034] The terms "about" or approximately" or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field; and

[0035] If the specification states a component or feature "may," "can," "could," "should," "would," "preferably," "possibly," "typically," "optionally," "for example," "often," or "might" (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

[0036] Embodiments relate generally to methods of manufacturing foldable, disposable face masks. In some embodiments, a method may comprise folding portions of the mask material and welding edges in a particular order to create the final, foldable mask shape. In other embodiments, the mask shape may be formed using a mold, wherein the molded mask shape comprises creases to allow for folding. Applicants have proposed methods for the manufacture of foldable masks that may be folded flat, making them easier to package, store, and carry. Additionally, the masks may be unfolded and refolded several times by a user, wherein the user may desire to keep the mask with him/her even if it is not being worn, for example by carrying the mask in a pocket or bag. The methods described may use polygon folding methods, and the final folded mask shape may be significantly smaller than current foldable mask shapes. By making a folded mask shape that is smaller and more compact, materials used when packaging the masks may be reduced and a variety of packaging options may be used.

[0037] Referring to FIGS. 1A-1D, exemplary embodiments of how an initial flat nonwoven material 100 is formed into a first foldable mask shape 120, a second foldable mask shape 130 and a third foldable mask shape 132. In some embodiments, mask shapes 130 and 132 may be similar, wherein mask shape 132 may be a further folded version of mask shape 130.

[0038] In some embodiments, the mask shape 100 may comprise a pentagon portion 101 having a lower triangular shape and an upper quadrilateral shape. The mask shape 100 may also comprise a first and second quadrilateral portion 102 and 103, wherein the first 102 and second 103 quadrilateral portions are proximate to the lower triangular portion of the pentagon portion 101 at a first crease 110 and a second crease 111. The mask shape 100 may also comprise a first trilateral portion 104 positioned between the first and second quadrilateral portions 102 and 103 proximate to the lower triangular shape of the pentagon portion 101.

[0039] The mask shape 100 may also comprise a second 105 and third 106 trilateral portion proximate to the upper quadrilateral shape of the pentagon portion 101 and the first quadrilateral portion 102. The first quadrilateral portion 102 and the second trilateral portion 105 may meet at a third crease 113, the pentagon portion 101 and the third trilateral portion 106 may meet at a fourth crease 112, and the second trilateral portion 105 and the third trilateral portion 106 may meet at a fifth crease 116. The mask shape 100 may also comprise a fourth and fifth trilateral portion 107 and 108 proximate to the upper quadrilateral shape of the pentagon portion 101 and the second quadrilateral portion 103. The second quadrilateral portion 103 and the fourth trilateral portion 107 may meet at a sixth crease 115, the pentagon portion 101 and the fifth trilateral portion 108 may meet at a seventh crease 114, and the fourth trilateral portion 107 and the fifth trilateral portion 108 may meet at an eighth crease 117.

[0040] In some embodiments, the mask shape 100 may be operable to be folded into one of three shapes. The first shape 120 may be formed by folding the first trilateral portion 104 along a ninth crease 123, nipping the first quadrilateral portion 102 and the second quadrilateral portion 103 together along a tenth crease 118 and an eleventh crease 119, and folding the quadrilateral portion 101 approximately in half along a twelfth crease 124. The second shape 130 may be formed by folding the second trilateral portion 105, the first quadrilateral portion 102, and the first trilateral portion 104 backward along creases 116, 110, and 122, and folding the fourth trilateral portion 107 and the second quadrilateral portion 103 backward along creases 117 and 111. The third shape 132 may be formed by forming the second shape 130 as described, folding the second trilateral portion 105 and the third trilateral portion 106 inwards along crease 116, and folding the fourth trilateral portion 107 and the a fifth trilateral portion 108 inwards along crease 117.

[0041] Methods disclosed herein may comprise steps of folding and welding to form a specific foldable mask shape. In the embodiment of FIGS. 2A-2C, a flat nonwoven fabric 200 may be provided or stamped with a plurality of creases 202, forming a mask shape 220. Creases 202 may be formed by any method of punching, stamping, rolling, etc. Additionally, the edges 204 of the mask shape 220 may be provided or stamped into the fabric 200. In some embodiments, the creases 202 and edges 204 of the mask shape 220 may be provided or stamped into the flat nonwoven fabric 200 using a rolling cutter process. In FIG. 2B, the excess fabric 201 may be removed from the mask shape 220 at the edges 204. In some embodiments, the excess fabric 201 may be cut away from the mask shape 220. When the excess fabric 201 is removed, as shown in FIG. 2C, the mask shape 220 may comprise a plurality of cut-outs 221, 222, and 223.

[0042] The method may continue, shown in FIGS. 3A-3C, wherein the mask shape 220 may comprise a first portion 302, a second portion 304 and a third portion 306. These portions may be defined by the cut-outs 221, 222 and 223. There may be a first crease 303 between the first portion 302 and second portion 304. There may be a second crease 305 between the second portion 304 and third portion 306. Additionally, the first portion 302 may comprise a crease 307, the second portion 304 may comprise a crease 311, and the third portion 306 may comprise a crease 309.

[0043] As shown in FIG. 3B, the method may comprise folding the first portion 302 onto the second portion 304 along the first crease 303 to align the edges of the first cut-out 221. The method may also comprise folding the third portion 306 onto the second portion 304 along the second crease 305 to align the edges of the second cut-out 222. The method may further comprise welding the edges of the first cut-out 221, such that the first portion 302 and the second portion 304 are now connected at the edges of the first cut-out 221. Additionally, the method may comprise welding the edges of the second cut-out 222, such that the second portion 304 and the third portion 306 are now connected at the edges of the second cut-out 222. As, shown in FIG. 3C, the first cut-out 221 may comprise edges AB and A'B' and the second cut-out may comprise edges CD and CD' .

[0044] In the embodiment shown in FIG. 3B, the first portion 302 and the third portion 306 may meet along the creases 307 (not shown) and 309 to form a fourth portion 308 and fifth portion 310. In the embodiment shown, the formation of the fourth portion 308 and fifth portion 310 may align the edges of the third cut-out 223. In other words, the edges of the third cut-out 223 may form one edge of the fourth portion 308 and fifth portion 310 of the mask shape 220. [0045] The method may continue as shown in FIGS. 3D-3G. In the embodiment shown, the fourth 308 and fifth 310 portions of the mask shape 220 may be folded onto the first portion 302 along the creases 309 and 307. Then, as shown in FIG. 3E, the edges of the third cut-out 223 may be welded. As shown in FIG. 3F, the third cut-out 223 may comprise edges EF and E'F'. Welding the edges of the three cut-outs 221, 222, and 223 may create a three-dimensional mask shape 220 from the originally flat nonwoven fabric 200, wherein the three-dimensional shape may fit about the face of a user. A further step of the method, as shown in FIG. 3G, may comprise folding the third portion 306 of the mask shape 220 and half of the second portion 304 of the mask shape 220 onto the fourth portion 308. The second portion 304 may fold in half along the crease 311. FIG. 3G illustrates a final folded mask shape 230 of the foldable, disposable mask. The mask may be packaged in this shape. Additionally, the mask may be unfolded from this shape to be worn by a user, and may be re-folded back into this shape when desired by the user, such as when the user wishes to carry the mask. The mask shape may be repeatedly unfolded and folded via the creases 202 of the mask shape.

[0046] In some embodiments, the method may further comprise attaching nose clips, head straps, and other additional parts, printing onto the mask fabric (such as a label or instructions for use), and the method may comprise packaging the folded mask. In some cases, a plurality of masks may be formed using this method and then packaged together in a group. In some embodiments, the methods described may be completely manually, and in other embodiments, they may be completed automatically. In yet other embodiments, some steps of the methods may be completed manually and some steps may be completed automatically.

[0047] Referring now to FIG. 4, and exemplary embodiment of the finished folded mask shape 230 is shown, wherein this specific example shows possible measurements for the folded mask shape 230. In some embodiments, the length 402 of the edges of the third cut-out 223 may be approximately 52 mm. Additionally, the angle 404 between the edges of the third cut-out 223 and the second crease 305 may be approximately 40 degrees. In some embodiments, the length 406 of the second crease 305 may be approximately 52 mm. Similarly, the first crease 303 may mirror the second crease 305 about the crease 311, and therefore may also be approximately 52 mm in length. Additionally, the angle 408 between the second crease 305 and the crease 311 may be approximately 40 degrees. In some embodiments, the length 410 of the edges of the second cut-out 222 may be approximately 58 mm. Similarly, the first cut-out 221 may mirror the second cut-out 222 about the crease 311, and therefore the edges of the first cut-out 221 may also be approximately 58 mm in length. Additionally, the angle 412 between the line created by the second crease 305 and the edges of the second cut-out 222 may be approximately 20 degrees. In some embodiments, the shape may comprise at least five creases, the total height of the shape 230 may not exceed 150 millimeters, and the total width of the shape 230 may not exceed 180 millimeters.

[0048] Additional methods disclosed herein may comprise steps of molding and folding to form a specific foldable mask shape. In the embodiment of FIGS. 5A-5D, a flat nonwoven fabric 500 may be molded to create a mask shape 520. In some embodiments, the step of molding may be accomplished by pressing the flat nonwoven fabric 500 between an upper part of the mold and a lower part of the mold. Additionally, the edges 504 of the mask shape 520 may be provided or stamped into the fabric 500. As shown in FIG. 5 A, the excess fabric 501 may be removed from the mask shape 520 at the edges 504. In some embodiments, the steps of molding and removing the excess fabric 501 may be accomplished simultaneously. Molding may create a three-dimensional mask shape from the flat nonwoven fabric material that fits about the face of a user.

[0049] In some embodiments, the molded mask shape 520 may comprise a plurality of creases 502 that allow for the mask shape 520 to fold along the creases 502. In the embodiment of FIG. 5C, the mask shape 520 may be folded into a first folded mask shape 521. In the embodiment of FIG. 5D, the mask shape 520 may be folded into a second folded mask shape 522. In some embodiments, the second folded mask shape 522 may be similar to the first folded mask shape 521, such that the second folded mask shape 522 may be created by further folding the first folded mask shape 521. The mask may be packaged in the shapes 521 and 522. Additionally, the mask may be unfolded from this shape to be worn by a user, and may be refolded back into this shape when desired by the user, such as when the user wishes to carry the mask. The mask may be repeatedly unfolded and folded via the creases 502 of the mask shape 520. In some embodiments, the method may further comprise attaching nose clips, head straps, and other additional parts, printing onto the mask fabric (such as a label or instructions for use), and the method may comprise packaging the folded mask. In some cases, a plurality of masks may be formed using this method and then packaged together in a group.

[0050] The method shown in FIGS. 6A-6D illustrates the formation of the first folded mask shape 521. In FIG. 6 A, a first portion of the mask 602 may be folded along a first set of creases 621, 622, and 623 to lay behind a second portion of the mask 604. The first portion 602 may comprise additional creases 624 and 625 that may facilitate in folding the first portion 602 behind the second portion 604 of the mask shape 520, as shown in FIG. 6A. In FIG. 6B, the first portion 602 is located behind the second portion 604. Then, in FIG. 6C, a third portion 606 of the mask shape 520 may be folded along a second set of creases 626 and 627 to lay behind the second portion 604 of the mask shape 520. The third portion 606 may comprise an additional crease 628 that may facilitate in folding the third portion 606 behind the second portion 604. These folding methods may form the first folded mask shape 521, as shown in FIG. 6D.

[0051] The method shown in FIGS. 7A-7D illustrates the formation of the second folded mask shape 522. In some embodiments, the method shown may be a continuation of the method shown in FIGS. 6A-6D, wherein the method may begin with the first folded mask shape 521, as shown in FIG. 7A. The method may comprise folding a fourth portion 608 and fifth portion 610 of the mask shape 520. The fifth portion 610 may be folded along a crease 626 as well as a set of creases 632 and 633, and may be folded between the second portion 604 and third portion 606 of the mask shape 520, as shown in FIG. 7B. The fourth portion 608 may be folded along a crease 621, as well as a set of creases 630 and 631, and may be folded between the first portion 602 and second portion 604 of the mask shape 520, as shown in FIG. 7C. These folding methods may form the second folded mask shape 522, as shown in FIG. 7D.

[0052] Referring now to FIG. 8, and exemplary embodiment of the finished first folded mask shape 521 is shown, wherein this specific example shows possible measurements for the mask shape 521. In some embodiments, the mask shape 521 may be symmetrical about an axis 802. In some embodiments, the length 804 of the crease 622 may be approximately 52 mm. Similarly, the crease 627 may mirror the crease 622 about the axis, and therefore may also be approximately 52 mm in length. Additionally, the angle 806 between the creases 622 and 627 may be approximately 80 degrees. In some embodiments, the length 808 of the crease 630 may be approximately 64 mm. Similarly, the crease 632 may mirror the crease 630 about the axis 802, and therefore may also be approximately 64 mm in length. Additionally, the angle 810 between the crease 603 and the line created by the crease 622 may be approximately 48 degrees. In some embodiments, the length 812 of the crease 621 may be approximately 58 mm. Similarly, the crease 626 may mirror the crease 621 about the axis 802, and therefore crease 626 may also be approximately 58 mm in length. Additionally, the angle 814 between the crease 621 and the line created by the crease 622 may be approximately 20 degrees. In some embodiments, the shape may comprise at least five creases, the total height of the shape 230 may not exceed 150 millimeters, and the total width of the shape 230 may not exceed 180 millimeters.

[0053] In some embodiments, the foldable masks formed by any of the methods described above may be packaged with other foldable masks for transport or sales of the masks. For example, the foldable masks described above may be more compact that traditional foldable masks, and therefore may be packaged in a smaller container. Additionally, the masks may be packaged in a container such that the masks are easy to individually remove from the container, similar to a facial tissue box. In another example, the masks may be packaged in a roll and may be individually removed or torn from the roll. In yet another example, the masks may be packaged to be sold individually from a vending machine.

[0054] While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

[0055] Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a "Field," the claims should not be limited by the language chosen under this heading to describe the so- called field. Further, a description of a technology in the "Background" is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the "Summary" to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to "invention" in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

[0056] Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Use of the term "optionally," "may," "might," "possibly," and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

[0057] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

[0058] Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.