Stiffened filter mask

• US 20040255946A1
• Filed: 07/16/2004
• Published: 12/23/2004
• Est. Priority Date: 06/05/2002
• Status: Active Grant

• Current Assignee: Louis M Gerson Company Incorporated (Louis M. Gerson)
• Original Assignee: Louis M Gerson Company Incorporated (Louis M. Gerson)
• Inventors: Brunell, Robert A., Gerson, Ronald L., Cupicha, Michael
• Granted Patent: US 7,677,248 B2
• Time in Patent Office: Days
• US Class Current: 128/205.27
• CPC Class Codes: A41D 13/1123 with a duckbill configuration
• CPC Class Codes: A41D 13/1138 with a cup configuration
• CPC Class Codes: A62B 23/025 the filter having substantially the shape of a mask surgical face masks A41D13/11
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A flat-folding mask includes a filter layer forming a rim. The filter layer has first and second side panels extending from the rim. A substantially centrally located front panel bridges the first and second side panels, the front panel being substantially flat. The filter layer further includes a fused portion that is seamless and spaced from the rim. Triangular pleats may add support to the side walls and increase the effective filtration area of the mask.

Claims

1. A flat-folding mask comprising:

a filter layer forming a rim and having;

first and second side panels extending from the rim;

a substantially centrally located front panel bridging the first and second side panels, the front panel being substantially flat; and

a fused portion spaced from the rim, the fused portion being seamless.

2. The mask according to claim 1, wherein the filter layer further comprises a first seam and a second seam extending from the rim.

3. The mask according to claim 1, further comprising a first and second pleat, the front panel bridging the first pleat and the second pleat.

4. The mask according to claim 3, wherein the wherein the filter layer further comprises a first and second seam, the first seam including a first non-linear portion for forming the first pleat, and the second seam includes a second non-linear portion for forming the second pleat.

5. The mask according to claim 3, wherein the filter layer has an effective center line that bisects the filter layer in a longitudinal direction, the first and second pleats being substantially bisected by the effective center line.

6. The mask according to claim 3, wherein at least one of the first pleat and the second pleat form a triangular shape.

7. The mask according to claim 1, wherein the fused portion substantially defines a perimeter of the front panel.

8. The mask according to claim 7, wherein the front panel within the perimeter does not include the fused portion.

9. The mask according to claim 1, wherein the front panel is generally parallel to the plane of a face a wearer when the mask is worn by the wearer.

10. The mask according to claim 1, wherein the fused portion includes a first fused portion and a second fused portion positioned within the front panel, the first fused portion and the second fused portion running substantially parallel to each other in a direction longitudinal to the front panel.

11. The mask according to claim 10, wherein the fused portion includes a third fused portion and a fourth fused portion positioned within the front panel, the third fused portion and the fourth fused portion running substantially parallel to each other in a direction latitudinal to the front panel.

12. The mask according to claim 1, wherein the fused portion includes a first fused portion and a second fused portion positioned within the front panel, the first fused portion and the second fused portion running substantially parallel to each other in a direction latitudinal to the front panel.

14. The mask according to claim 1, wherein the fused portion includes at least one fused portion positioned within the first and second side panel, the at least one fused portion extending substantially from the rim to the front panel.

15. The mask according to claim 1, wherein during use the mask is capable of forming a cup-shaped air chamber over a nose and a mouth of a wearer.

16. The mask according to claim 1, wherein the fused portion is unpleated.

17. The mask according to claim 1, further comprising at least one layer of material attached to the filter layer.

18. The mask according to claim 17, wherein the at least one layer of material includes spunbonded polypropylene.

19. The mask according to claim 17, wherein the at least one layer of material includes olefin.

20. The mask according to claim 1, wherein the filter layer is a single, contiguous sheet of material.

21. The mask according to claim 1, further comprising a valve attached to the front panel.

22. The mask according to claim 1, further comprising a support base that supports the filter layer.

23. The mask according to claim 1, wherein the filter layer further includes a first tab and a second tab that extend seamlessly from the rim.

24. The mask according to claim 23, the mask further comprising:

a headstrap attached to the first tab and the second tab.

25. The mask according to claim 23, wherein the tabs are generally perpendicular to the front panel when the rim of the mask is pulled open.

26. The mask according to claim 23, wherein the filter layer forms at least two side panels that extend from the rim to the front panel, the first tab and the second tab extending from the same side panel.

13. The mask according to claim 13, wherein the first side panel is a top side panel, the second side panel is a bottom side panel, the mask further comprising a right side panel and a left side panel.

27. A mask comprising:

a filter layer forming a rim, the filter layer including;

a first seam and a second seam extending from the rim,

a front panel between the first seam and the second seam,

a first and second pleat, the front panel adjoining the first and second pleat,

wherein the filter layer includes a fused portion being seamless and spaced from the rim,

28. The mask according to claim 27, wherein the front panel is substantially flat.

29. The mask according to claim 27, wherein the front panel is generally parallel to a face of a wearer when the mask is worn by the wearer

30. The mask according to claim 27, wherein the mask is capable of being folded flat for storage.

31. The mask according to claim 27, further comprising a support base that supports the filter layer.

32. The mask according to claim 31, wherein the support base forms a base rim, the rim of the filter layer being secured to the base rim.

33. The mask according to claim 31, further comprising a valve extending through the filter layer and the support base.

34. The mask according to claim 27, further comprising at least one layer of material, the at least one layer of material and the filter layer being attached.

35. The mask according to claim 27, wherein the filter layer is a single sheet of material.

36. The mask according to claim 27, wherein the filter layer includes first and second complimentary portions that form the rim and the front panel, the first portion being connected to the second portion at the first and the second seams.

37. The mask according to claim 36, wherein the first and second portions further form a top side panel and a bottom side panel, the top side panel and the bottom side panel extending from the rim to the front panel.

38. The mask according to claim 37, wherein the first and second portions further form a left side panel that includes the first seam and a right side panel that includes the second seam, the first pleat folded over the left side panel, and the second pleat folded over the right side panel.

39. The mask according to claim 38, wherein the first pleat extends from the front panel towards the rim and is attached to the left side panel, and wherein the second pleat forms a second fold that extends from the front panel towards the rim and is attached to the right side panel.

40. The mask according to claim 27, wherein the fused portion includes at least one fused portion that extends substantially from the rim to the front panel, such that the mask stands away from the rim.

41. The mask according to claim 27, wherein the fused portion includes at least one fused portion that is positioned within the front panel.

42. The mask according to claim 41, wherein the fused portion positioned within the front panel substantially forms at least one of a rectangle, a square, a rhombus, and a circle.

43. The mask as defined by claim 27, wherein the filter layer has an effective center line that bisects the filter layer in a longitudinal direction, the first and second seams being substantially coincident with the effective center line.

44. The mask as defined by claim 27, wherein the filter layer has an effective center line that bisects the filter layer in a longitudinal direction, the first and second pleats being substantially bisected by the effective center line.

45. The mask according to claim 27, wherein the filter layer further includes a first tab and a second tab that extend seamlessly from the rim.

46. The mask according to claim 45, wherein the mask further includes:

a head strap attached to the first tab and the second tab.

47. The mask according to claim 45, wherein the tabs are generally perpendicular to the front panel when the rim of the mask is pulled open.

48. The mask according to claim 45, wherein the filter layer forms at least two side panels that extend from the rim to the front panel, the first tab and the second tab extending from the same side panel.

49. The mask according to claim 27, wherein at least one of the first pleat and the second pleat form a triangular shape.

107. The mask according to claim 27, wherein the filter layer includes first and second complimentary portions that form the rim and the front panel, the first portion being connected to the second portion at the first and the second seams.

108. The mask according to claim 36, wherein the first and second portions further form a top side panel and a bottom side panel, the top side panel and the bottom side panel extending from the rim to the front panel.

109. The mask according to claim 37, wherein the first and second portions further form a left side panel that includes the first seam and a right side panel that includes the second seam, the first pleat folded over the left side panel, and the second pleat folded over the right side panel.

110. The mask according to claim 38, wherein the first pleat extends from the front panel towards the rim and is attached to the left side panel, and wherein the second pleat forms a second fold that extends from the front panel towards the rim and is attached to the right side panel.

50. A method of manufacturing a mask having a filter layer, the method comprising:

folding the filter layer to form two sections, each section having two ends and one side;

reshaping the two ends of each section to form two reshape lines, each of the two reshape lines having a non-linear portion; and

connecting the two sections along the two reshape lines such that the two sections form a pocket having a rim, wherein when the pocket is open at least two side panels extend from the rim to a front panel.

51. The method according to claim 50, wherein folding the filter layer includes folding along a center line running longitudinal to the front panel.

52. The method according to claim 50, further comprising forming at least one pleat.

53. The method according to claim 52, wherein forming the at least one pleat includes forming a first pleat and a second pleat, the front panel adjoining the first pleat and the second pleat.

54. The method according to claim 52, wherein the at least one pleat has a distal end, further comprising attaching the distal end of the at least one pleat to a portion of the filter material between the rim and the front panel.

55. The method according to claim 52, wherein forming the at least one pleat includes folding the reshape lines across the non-linear portion.

56. The method according to claim 50, further comprising fusing an unpleated portion of the filter layer, the fused unpleated portion being seamless and stiffer relative to a second portion of the filter layer.

57. The method according to claim 56, wherein fusing occurs prior to the step of folding.

58. The method according to claim 56, wherein fusing occurs subsequent to the step of folding.

59. The method according to claim 56, wherein fusing includes ultrasonic welding.

60. The method according to claim 56, wherein fusing the unpleated portion includes fusing a first and second portion in the front panel, the first and second portions being substantially parallel.

61. The method according to claim 60, wherein the first and second unpleated portions run substantially parallel to each other in a direction longitudinal to the front panel

62. The method according to claim 60, wherein first and second unpleated portions run substantially parallel to each other in a direction latitudinal to the front panel.

63. The method according to claim 56, wherein fusing the unpleated portion includes fusing at least one unpleated portion running substantially from the rim to the front panel.

64. The method according to claim 63, further comprising pulling on the rim to open the pocket.

66. The method according to claim 50, further comprising reshaping the side of one of the sections to form a first tab and a second tab, the first tab and the second tab extending seamlessly from the rim.

67. The method according to claim 66, further comprising attaching a headstrap to the first tab and the second tab.

68. The mask according to claim 66, wherein further comprising folded the first tab and the second tab substantially near the rim.

69. The mask according to claim 50, wherein the non-linear portion is concave.

70. The mask according to claim 50, wherein the non-linear portion is convex.

71. The product formed by the process of claim 50.

65. The method according 50, wherein the front panel is substantially flat.

72. A method of manufacturing a mask having a filter layer, the method comprising:

forming a fused portion in the filter layer, the fused portion being seamless;

connecting two planar surfaces of the filter layer to form a pocket having a rim, the fused portion spaced from the rim; and

pulling on the rim to open the pocket, the filter layer forming at least three side panels that extend from the rim to define a perimeter of a front panel.

73. The method according to claim 72, wherein the front panel is substantially flat.

74. The method according to claim 72, wherein the at least three side panels include a top side panel, a bottom side panel, a left side panel, and a right side panel.

75. The method according to claim 72, wherein forming the fused portion includes forming a first and second fused portion in the front panel, the first and second fused portions being substantially parallel.

76. The method according to claim 75, wherein the first and second fused portions run substantially parallel to each other in a direction longitudinal to the front panel.

77. The method according to claim 75, wherein first and second fused ortions run substantially parallel to each other in a direction latitudinal to the front panel.

78. The method according to claim 72, wherein forming the fused portion includes forming at least one fused portion running substantially from the rim to the front panel.

79. The method according to claim 72, wherein forming the fused portion includes fusing substantially a perimeter of the front panel, wherein the front panel within the perimeter does not include the fused portion.

80. The method according to claim 72, further comprising forming a first pleat and a second pleat, the first pleat connected to the second pleat by the front panel.

81. The method according to claim 72, further comprising reshaping one of the two planar surfaces to form a first tab and a second tab extending seamlessly from the rim.

82. The method according to claim 81, further comprising attaching a headstrap to the first tab and the second tab.

83. The mask according to claim 81, further comprising folding the first tab and the second tab substantially near the rim.

84. The mask according to claim 72, wherein the fused portion is unpleated.

85. The product formed by the process of claim 72.

86. A mask comprising:

a filter layer forming a rim, the filter layer including;

a front panel;

at least one side panel extending from the rim to the front panel; and

a first tab and a second tab extending seamlessly from the rim.

87. The mask according to claim 86, wherein the front panel is substantially flat.

88. The mask according to claim 86, further comprising a headstrap attached at the first tab and the second tab.

89. The mask according to claim 86, wherein the first tab and the second tab are generally perpendicular to the front panel when the rim of the mask is pulled open.

90. The mask according to claim 86, wherein the filter layer forms at least two side panels that extend from the rim to the front panel, the first tab and the second tab extending from the same side panel.

91. A flat-folding mask comprising:

a rim;

a front panel spaced from the rim and being substantially centrally positioned, the front panel being substantially flat; and

a seamless fused portion spaced from the rim,

the mask capable of folding substantially flat when not in use,

the mask capable of opening for use after being folded flat, the mask when open forming a recess defined by the rim.

92. The mask according to claim 91, further comprising a top and bottom side panel extending from the rim to the front panel.

93. The mask according to claim 92, further comprising a right and left side panel.

94. The mask according to claim 93, where the seamless fused portion substantially extends from the rim to the front panel.

95. The mask according to claim 91, further comprising a first and second pleat, the front panel bridging the first pleat and the second pleat.

96. The mask according to claim 95, wherein the filter layer has an effective center line that bisects the filter layer in a longitudinal direction, the first and second pleats being substantially bisected by the effective center line.

97. The mask according to claim 91, wherein the fused portion includes a first fused portion and a second fused portion positioned within the front panel, the first fused portion and the second fused portion running substantially parallel to each other in a direction longitudinal to the front panel.

98. The mask according to claim 91, wherein the fused portion includes a third fused portion and a fourth fused portion positioned within the front panel, the third fused portion and the fourth fused portion running substantially parallel to each other in a direction latitudinal to the front panel.

99. The mask according to claim 91, wherein the fused portion includes a first fused portion and a second fused portion positioned within the front panel, the first fused portion and the second fused portion running substantially parallel to each other in a direction latitudinal to the front panel.

100. The mask according to claim 91, wherein the fused portion is unpleated.

101. A mask comprising:

a filter layer forming a rim and having;

a front panel spaced from the rim, and

a first triangular pleat adjoining the front panel.

102. The mask according to claim 101, wherein the front panel is substantially flat.

103. The mask according to claim 101, wherein the mask is capable of being folded flat for storage.

104. The mask according to claim 101, further comprising a second triangular pleat, the front panel adjoining the first and second triangular pleat.

105. The mask according to claim 101, further comprising a side panel, the triangular pleat attached to the side panel.

106. The mask according to claim 105, wherein the triangular pleat includes a distal end, a top side, and an underside, and wherein the triangular pleat is attached at the distal end to the side panel such that the triangular pleat is open on both the topside and the underside.