CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This international patent application claims the benefit of the filing dates of U.S. Provisional Patent Application No. 63/107,521 filed October 30, 2020 and Indian Design Patent Application No. 329875-001 filed on June 8, 2020, the entire contents of both which are hereby incorporated by reference.

FIELD

[0002] This application relates generally to personal respirator masks.

DESCRIPTION OF RELATED ART INCLUDING INFORMATION DISCLOSED

UNDER 37 CFR 1.97 AND 1.98

[0003] Common respirator masks designed for everyday use exhibit several significant problems when used for long periods. Among other problems, respirator masks block view of much of a user’s facial expressions, hindering communication. Condensation and humidity build up due to entrapment of the user’s exhalation, and masks cannot detect, or keep up with, changes in the mask’s air quality caused, for example, by periods of exercise. Known arrangements of straps and loops for securing masks to a user’s head often bite into the most sensitive areas of the user’s face, leaving bruising and abrasions that may become severe with prolonged use. Finally, many recent mask designs include designs for sanitizing the mask with UV light, but fail to target a mask’s filter or make adequate provisions to protect the user from ozone created by UV illumination.

SUMMARY

[0004] A respirator mask may comprise a mask shell configured to cover the nose and mouth of a user while the user is wearing the mask, a perimeter of the mask shell being configured to rest against the face of the user while the user is wearing the mask and a transparent portion of the mask shell being positioned such that the mouth of the user is visible through the mask while the user is wearing the mask. A mask retainer is attached to the mask shell at retainer attachment points disposed on the mask shell, the mask retainer being configured to hold the mask against the user’s face. A filter is carried by the mask shell in a position where the filter is disposed adjacent a chin of the user without obstructing a view of the user’s mouth from a point forward of the user while the user is wearing the mask.

[0005] The mask may comprise strap standoffs carried by the mask retainer in respective positions that will permit the strap standoffs to rest against underlying portions of the user’s head when the user is wearing the mask. And the strap standoffs may be configured to space at least part of the mask retainer from underlying portions of the user’s face so that, when the mask is worn by a user, the standoffs relieve inward pressure that would otherwise be applied to underlying portions of the user’s face by respective portions of the mask retainer extending between the standoffs and the mask shell.

[0006] The mask shell may comprise a flexible material, and a mask perimeter wire may adjustably support a shape of at least a portion of the mask shell perimeter extending from at least a location below one of the retainer attachment points, across the user’s nose, and at least to a location below another of the retainer attachment points. The wire may be adaptable to adjustably retain the wire-supported part of the mask shell perimeter in a shape corresponding to facial contours of the user.

[0007] The mask may comprise a ventilation module comprising a blower and fdter carried by the mask shell in respective positions such that the blower is in fluid communication with the fdter, and air passes through the mask shell by flowing through the blower and fdter. One or more sensors may be carried by the mask shell, and an active ventilation controller may be connected in communication with both the sensor and the blower, and configured to send commands to the blower in response to signals received from the sensor.

[0008] A UV light may be carried by the mask shell and positioned to illuminate an exterior side of the fdter. And the mask may include a safety device configured to permit the UV light to be illuminated only when a pre-determined condition has been satisfied. DRAWING DESCRIPTIONS

[0009] Figure 1 is a front view of a respirator mask;

[0010] Figure 2 is a side view of the mask of Figure 1 shown as worn by a user;

[0011] Figure 3 is a top view of the mask of figure 1 ;

[0012] Figure 4 is a bottom view of the mask of Figure 1;

[0013] Figure 5 is a front perspective view of the mask of Figure 1 ;

[0014] Figure 6 is a back perspective view of the mask of Figure 1, additionally showing attached headstraps and standoffs;

[0015] Figure 7 shows an alternative embodiment of a respirator mask configured with ear loops instead of headstraps;

[0016] Figure 8 is a top-down view of the mask of Figure 1 shown as worn by a user;

[0017] Figure 9 is a perspective exploded view of the mask of Figure 1 ;

[0018] Figure 10 is a closeup rear perspective view of the mask of Figure 1, showing elements of a ventilation module through a partially transparent representation of a filter;

[0019] Figure 11 is a partial schematic view of the components connected to and carried by the ventilation module of Figure 10.

DETAILED DESCRIPTION

[0020] Various embodiments of a respirator mask are generally shown at 10 in the Figures. To show similarities between embodiments, elements that are shared by multiple embodiments are marked with matching indicator numbers, while the presence of prime indicators in superscript indicates which embodiment they belong to. For example, the number 42 may refer to a component of a first embodiment that is analogous to component 42' of a second embodiment. Portions of the detailed description that refer to 42 may therefore also apply to 42', etc. [0021] The respirator mask 10 comprises a mask shell 12 configured to cover the nose and mouth of a user while the user is wearing the mask 10. A perimeter 14 of the mask shell 12 is configured to rest against the face of the user while the user is wearing the mask 10. And a mask retainer 16, configured to hold the mask 10 against the user’s face, is attached to the mask shell 12 at retainer attachment points 18 disposed on the mask shell 12.

[0022] A transparent portion 20 of the mask shell 12 may be positioned such that the mouth of the user is visible through the mask 10 while the user is wearing the mask 10. This transparent portion 20 may comprise as much as the entirety of the mask shell 12. A main filter 22 may also be carried by the mask shell 12 in a position where the filter 22 is disposed adjacent a chin of the user (while the user is wearing the mask 10, as best shown in Fig. 2) without obstructing a view of the user’s mouth from a point forward of the user. This filter location, combined with the transparent mask shell portion 20, allows the mask 10 to provide protection against airborne contaminants without substantially visually obstructing the user’s facial expressions.

[0023] Several types of coatings may be applied to the transparent portion 20 of the mask shell 12. For example, anti-fog, anti-scratch, hydrophobic, and/or anti-UV coatings may be applied to prevent fog, condensation, physical damage, sunburn to the user, or degradation of mask components.

[0024] The respirator mask 10 may also include one or more side ports 24 carried by the mask shell 12 in positions where the side ports 24 will be disposed to the sides of the user’s mouth while the user is wearing the mask 10. These side ports 24 may also be positioned so that they will not obstruct the user’s mouth from view. Depending on the user’s needs, these side ports 24 may be configured to receive one or more types of inserts. As best shown in Figure 9, these inserts may, for example, include exhaust valves 26 to provide easier exhalation, side port filters 28 to filter exhaled air, and/or airtight plugs 30 to force all air to move through the main filter 22.

[0025] To better fit the faces of different users, the mask shell 12 may comprise a flexible material, such as a silicone compound. This flexible material may preferably have a hardness value falling in a range of 40-80 °Sh. This flexible mask shell 12 may include a mask shell perimeter wire 32, shown in Figure 9, that may be at least partially embedded within at least a portion of the mask shell perimeter 14, and the mask shell perimeter wire 32 may adjustably support the shape of at least part of the mask shell perimeter 14 along a length of the mask shell perimeter 14 extending at least from a position below one of the retainer attachment points 18, across the user’s nose, and at least to a position below another of the retainer attachment points 18. However, the mask perimeter wire 32 may support as much as the entire mask shell perimeter 14. Or, as disclosed in the preferred embodiment shown in Figure 9, the mask perimeter wire 32 may support the mask shell perimeter 14 along its entire length except for the length adjacent the fdter 22, where the fdter 22 itself may provide support.

[0026] The perimeter wire 32 may include and/or be formed from a malleable material, such as an aluminum alloy, that is adaptable to adjustably retain the wire -supported part of the mask shell perimeter 14 in a shape corresponding to facial contours of the user. The combination of the soft material and support provided by the perimeter wire 32, allows the mask 10 to be formed into, and to retain, a comfortable shape capable of maintaining a good seal against the user’s skin. The perimeter wire 32 may be formed into lengths having any cross-sectional shape (such as circular, oval, rectangular, flanged, etc.) suitable for this purpose.

[0027] The mask retainer 16 may comprise head strap configurations, one example of which is shown in Figures 6 and 8, or an ear loop configuration, as shown in Figure 7.

[0028] Where the mask retainer 16 comprises a head strap configuration, the mask retainer 16 may also comprise forward head strap portions 34 connected to the mask shell 12 at the retainer attachment points 18, and a rear head strap portion 36 connected to and integrally extending from and between the forward head strap portions 34. At least part of the rear head strap portion 36 may have a higher elasticity and/or softness than the forward head strap portions 34. For example, the hardness values of the forward head strap portions 34 and the rear head strap portion 36 may be 60 °Sh, and 10 °Sh, respectively. In the preferred embodiment shown in Figures 6 and 8, two rear head straps 36 may be paired with four forward strap portions 34, but in other embodiments, any number of forward 34 and rear 36 straps may be used. [0029] Where the mask retainer 16 comprises an ear loop configuration, the mask retainer 16 may comprise forward loop end portions 38 connected to the mask shell 12 at the respective retainer attachment points 18, and two ear loops 40 connected to and integrally extending from respective forward loop end portions 38, and may be configured to loop around and engage the user’s ears. At least part of each ear loop 40 may have a higher elasticity and/or softness value than that of the forward loop end portion 38 it is connected to.

[0030] In either configuration, the retainer 16 may also comprise strap standoffs 42 located on the mask retainer 16 in respective positions that space the mask retainer 16, or at least a part thereof, from underlying portions of the user’s face, as best shown in Figure 8 so that the standoffs 42 relieve inward pressure that would otherwise be applied to underlying portions of the user’s face by respective portions of the mask retainer 16 extending between the standoffs 42 and the mask shell 12. This spacing may also be sufficient to prevent the forward head strap portions 34 from pressing against the underlying portions of the user’s face adjacent to the standoffs.

[0031] To provide similar spacing adjacent the mask shell perimeter 14, the retainer attachment points 18 may also be spaced from the mask shell perimeter 14 (for example, in a forward and/or outward direction relative to the user’s head) so that, when the user is wearing the mask 10, the mask retainer 16 will not touch respective underlying portions of the user’s face adjacent the retainer attachment points 18. The retainer attachment points 18 and standoffs may even be positioned so that, when the user is wearing the mask 10, the mask retainer 16 does not touch portions of the user’s face underlying respective portions of the mask retainer 16 between each retainer attachment point 18 and its adjacent respective standoff 42.

[0032] Where the mask retainer 16 comprises a headstrap configuration, the standoffs 42 may be carried by the mask retainer 16 in respective positions where the forward head strap portions 34 connect to and/or integrally extend from the rear head strap portions 36. And the spacing of the retainer attachment points 18 and standoffs 42 may be sufficient to ensure that no part of the forward strap portions 34 touches respective underlying portions of the user’s face when the user is wearing the mask 10. [0033] Where the mask retainer 16 comprises an ear loop configuration, the standoffs may be carried by the mask retainer 16 in respective positions where the forward loop end portions 38 connect to and/or integrally extend from the ear loops 40. And the spacing of the retainer attachment points 18 and standoffs 42 may be sufficient to ensure that no part of the forward loop end portions 38 touches respective underlying portions of the user’s face when the user is wearing the mask 10.

[0034] These configurations of the standoffs 42 and retainer attachment points 18 redirect force that might otherwise cause the mask retainer 16 to cut or press into the flesh of the user’s face. Thanks to the spacing of the retainer attachment points 18, this force may instead be spread out across the mask shell perimeter 14, where it can be more evenly distributed by the perimeter wire 32, which may be configured and located to distribute inward force from the retainer attachment points 18 across the mask shell perimeter 14 where the shell perimeter 14 contacts the face of a user. Some of this redirected force may also be taken up by the strap standoffs 42, which may rest on portions of the user’s head that are less sensitive or prone to marking than the face. The relative hardness or inelasticity of the forward strap 34 (or loop 38) portions allows the standoffs 42 to remain at a relatively constant distance from the mask shell 12 even as the more elastic portions of the mask retainer 16 are stretched to secure the mask 10 to the user’s head. This prevents potential discomfort that might occur if the standoffs 42 were able to move around and pull on the user’s face.

[0035] The mask 10 may also include a ventilation module 44 comprising a blower 46 and fdter 22 that may be mounted in the mask shell 12 and may be carried by the mask shell 12 in respective positions such that the blower 46 is in fluid communication with the filter 22, and air passes through the mask shell 12 by flowing through the blower 46 and filter 22. The ventilation module 44 may also comprise one or more sensors that may be carried by the mask shell 12, and an active ventilation controller 48 that may be connected in communication with both the sensors and the blower 46. The active ventilation controller 48 may be configured to send commands to the blower 46 in response to signals received from the sensors. [0036] The sensors of the ventilation module 44 may include an internal humidity sensor 50 positioned to sense humidity of gasses disposed between the mask 10 and a user’s face, and an external humidity sensor 52 positioned to sense ambient air humidity. The resulting internal and ambient humidity readings may be sent to the active ventilation controller 48, which may be configured to adjust blower 46 speed in response to changes in the difference between humidity detected by the internal sensor 50 and humidity detected by the external humidity sensor 52. In this way, blower 46 speed may be increased as necessary to prevent or reduce condensation, and render the air more comfortable to breathe. The active ventilation controller 48 may also or alternatively be programmed to reverse blower 46 direction if the detected difference in humidity reaches a pre-set threshold, allowing for rapid replacement of humid air.

[0037] The ventilation module 44 may also or alternatively include a sound sensor 54, and the active ventilation controller 48 may be configured to adjust blower 46 speed in response to a pre-determined sound volume detected by the sound sensor 54. This arrangement may be used to keep noise from the blower 46 to an unobtrusive level. For example, the pre-determined sound volume may be indexed to a desired sound volume level that would be perceived at a desired distance from the blower 46, and the active ventilation controller 48 may be configured to restrict blower 46 speed to ensure that the sound volume of the blower 46 detected by the sound sensor 54 does not exceed the predetermined sound volume (i.e.: a desired volume of 30db at lm from the blower 46 may be indexed to a volume of 50db detected by the sound sensor 54, which lies closer to the blower 46, so the controller 48 may be configured to keep detected sound at or below 50db in order to keep desired sound at lm at or below 30db). This desired sound volume level may also correspond to a sound volume level of ambient noise detected by the sound sensor 54. In this way, the mask 10 may be configured so that a person standing, for example, lm away from a user wearing the mask 10, would perceive the blower 46 noise from the mask 10 to be no louder than the ambient sound environment.

[0038] The ventilation module 44 may also or alternatively include an internal air pressure sensor 56 positioned to sense air pressure between the mask 10 and a user’s face, and an exterior air pressure sensor 58 positioned to sense ambient air pressure. The active ventilation controller 48 may be configured to adjust blower 46 speed in response to changes in the difference in pressure reported by the internal 56 and external 58 air pressure sensors. Significant pressure differentials may be caused by a clogged filter 22, so the active ventilation controller 48 may also be configured to send a signal recommending filter 22 replacement, in response to a pre-determined difference in pressure reported by the internal 56 and external 58 air pressure sensors.

[0039] The ventilation module 44 may also or alternatively comprise air quality sensors 60 capable of measuring the presence of specific substances in air passing through the mask 10. For example, the air quality sensor 60 may be a sensor configured to detect volatile organic compounds, or carbon dioxide. Where an air quality sensor 60 is a carbon dioxide sensor, it may provide the active ventilation controller 48 with data on carbon dioxide levels, and the active ventilation controller 48 may determine metabolic data about the user based on the carbon dioxide data. A pulse oximeter 62 may also or alternatively be carried by the ventilation module 44 to provide user metabolic data.

[0040] Data collected or derived by the active ventilation controller 48 and any of the sensors described above may be stored in a memory unit 64 that may be carried by or with or included in the active ventilation controller 48, and/or transmitted via a wireless transmitter 66 that may be carried by the active ventilation controller 48. And the active ventilation controller 48 may further include a wireless receiver 68 to receive data and commands. Via the wireless transmitter 66 and receiver 68, the active ventilation controller 48 may be configured to exchange data and commands remotely with any of the sensors discussed above, and/or with a remote device 70 including a user interface.

[0041] The active ventilation controller 48 may also be configured to receive and execute user commands from the remote device 70, and/or user inputs made to the mask 10 itself via physical switches and/or buttons 72 carried by the mask 10, and/or a gesture sensor 74 carried by the mask 10. These user commands may comprise instructions to adjust blower 46 speed, or activate different active ventilation controller 48 modes, for example a user command to enable “silent mode” may instruct the active ventilation controller 48 to keep blower 46 noise below ambient noise, as described above. [0042] To sanitize the filter 22, a UV light 76 (which may be a UV-C emitter) may be carried by the mask 10 and positioned to illuminate an interior and/or exterior side of the filter 22. In the example shown in Figure 10, the UV light 76 may be carried on the ventilation module 44 and positioned under the main filter 22 to illuminate the exterior side of the filter 22. A rechargeable battery 78 may also be carried by the mask 10 and connected to the UV light 76 and/or the ventilation module 44 if present. As shown in Figure 11, a charging port 80 may be connected to the battery 78. A charging port connection detector 82 may be configured to detect a connection to the charging port 80 and, in response, send a connection detected signal to a safety device 84.

[0043] To prevent harm to the user, the mask 10 may also carry the safety device 84, which may be configured to permit the UV light 76 to be illuminated only when a pre determined condition has been satisfied. This pre-determined condition may be an indication that the user is not wearing the mask 10. For example, the pre-determined condition may comprise receipt of a connection detected signal from the charging port connection detector 82 (which may indicate that the mask 10 has been placed on a charging stand). The pre determined condition may include other criteria as well, including, for example, a ten-minute delay after receipt of a connection signal from the charging port connection detector 82.

[0044] This description, rather than describing limitations of an invention, only illustrates an embodiment of the invention recited in the claims. The language of this description is therefore exclusively descriptive and is non-limiting. Obviously, it’s possible to modify this invention from what the description teaches. Within the scope of the claims, one may practice the invention other than as described above.