Disposable face mask with enhanced fluid barrier

• US 6,055,982 A
• Filed: 12/18/1997
• Issued: 05/02/2000
• Est. Priority Date: 12/15/1993
• Status: Expired due to Term

• Current Assignee: Avent Incorporated (Avanos Medical, Inc.)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Rich, Albert R., Reese, George D., Brunson, Kevin K., Rasberry, Frank D.
• Primary Examiner(s): Weiss, John G.
• Assistant Examiner(s): SRIVASTAVA, VIRENDRA KUMAR
• Application Number:
  US08/994,231
• Time in Patent Office: 866 Days
• Field of Search: 128/206.12, 128/206.13, 128/206.17, 128/206.19, 128/206.21, 128/206.22, 128/206.24, 128/206.25, 128/207.11
• US Class Current: 128/206.12
• CPC Class Codes: A41D 13/1115 with a horizontal pleated pocket
• CPC Class Codes: A41D 13/1123 with a duckbill configuration
• CPC Class Codes: A41D 13/1176 forming a complete seal at the edges of the mask
• CPC Class Codes: A41D 13/1184 with protection for the eyes, e.g. using shield or visor
• CPC Class Codes: A61F 9/029 Additional functions or features, e.g. protection for other parts of the face such as ears, nose or mouth; Screen wipers or cleaning devices

Abstract

A disposable face mask that includes a filter body capable of filtering liquids and/or particles of a size appropriate for the mask'"'"'s intended purposes, while providing excellent breathability and comfort to the wearer for extended periods of time. The filter body is formed from multiple layers of filtration material having various configurations. Such masks may be secured by one or more knitted headbands to the head of a wearer. Various gasket-type sealing materials such as plastic film or other materials such as hydrogel may be used to enhance the fluid barrier formed between the periphery of the mask and the wearer'"'"'s face. For one embodiment the face mask may include a continuous loop of material to secure the mask on a wearer'"'"'s face.

Claims

1. A disposable face mask comprising:

a filter body having an opening sized to cover the nose and mouth of a wearer, the body having top and bottom edges with the top edge arranged to extend across the nose of the wearer and the bottom edge arranged to extend under the chin of the wearer;

the top edge having ends opposite from each other and the bottom edge having ends opposite from each other;

first securing means attached to the filter body adjacent to each end of the top edge and arranged to extend generally about the back of the head of the wearer in an approximate linear continuation from the top edge, the first securing means for urging the top edge into tight engagement with the wearer to prevent fluid flow between the top edge and the wearer;

second securing means attached to the filter body adjacent to each end of the bottom edge and arranged to extend generally over the top of the head of the wearer in an approximate linear continuation from the bottom edge, the second securing means for urging the bottom edge into tight engagement with the wearer to prevent fluid flow between the bottom edge and the wearer;

the filter body comprising an upper portion of generally trapezoidal configuration having a longer side forming the top edge and a lower portion of generally trapezoidal configuration having a longer side forming the bottom edge;

the upper and lower portions being joined along all remaining sides;

a plurality of radii formed on opposite sides of the filter body extending from the opening;

a first strip of sealing material disposed within the filter body adjacent to the opening and extending along the top edge;

a second strip of sealing material disposed within the filter body adjacent to the opening and extending along the bottom edge; and

the first sealing strip and the second sealing strip cooperating with each other to form a fluid barrier between the opening of the filter body and the face of the wearer.

2. The mask of claim 1 further comprising a visor attached thereto to protect the eyes and exposed portions of the wearer'"'"'s face.

3. The mask of claim 1 further comprising:

a portion of the first strip of sealing material extending from the opening; and

a portion of the second strip of sealing material extending from the opening.

4. The mask of claim 1 wherein the filter body further comprises an intermediate layer of material which is gas permeable in both directions through the filter body and liquid impermeable in the direction from outside the filter body to inside the filter body.

5. The mask of claim 1 wherein the filter body further comprises an intermediate layer of filter media formed from expanded polytetrafluoroethylene (PTFE).

6. The mask of claim 5 wherein the filter body further comprises a first layer of bicomponent material disposed on one side of the intermediate layer of expanded polytetrafluoroethylene and a second layer of the same bicomponent material disposed on the opposite side of the layer of expanded polytetrafluoroethylene.

7. A disposable face mask comprising:

a filter body sized to fit over the mouth and nose of a wearer, the filter body having a top edge and a bottom edges with the top edge arranged to extend across the nose and cheeks of the wearer and the bottom edge arranged to extend under the chin of the wearer;

the filter body having a pair of lateral edges extending between the top edge and the bottom edge;

a first strip of sealing material disposed on the interior of the filter body adjacent to and extending along the top edge;

a second strip of sealing material disposed on the interior of the filter body adjacent to and extending along the bottom edge;

a flap attached to each lateral edge of the filter body and arranged to extend from the filter body;

each flap folded to define a generally U-shaped section;

securing means defined in part by a continuous loop of material disposed within the U-shaped section of each flap and arranged to extend generally about the head of the wearer, the securing means cooperating with the flaps for urging the first strip of sealing material on the top edge and the second strip of sealing material on the bottom edge into tight engagement with the wearer to prevent undesired fluid flow between the top edge and the bottom edge and the wearer'"'"'s face; and

the flaps cooperating with the securing means to prevent undesired fluid flow between the respective lateral edges of the filter body and the face of the wearer.

8. The mask of claim 7 wherein the first strip of sealing material and the second strip of sealing material further comprise a thin layer of plastic film with a portion of the first strip of material and a portion of the second strip of sealing material extending respectively from the top edge and the bottom edge of the filter body.

9. The mask of claim 7 further comprising an elongated malleable member located in the top edge for conforming the top edge to the contours of the wearer'"'"'s nose and cheeks.

10. The mask of claim 7 wherein the first strip of sealing material and the second strip of sealing material comprises hydrogel.

11. The mask of claim 7 wherein the filter body comprises a layer of filter media for restricting the flow of liquids through the filter body.

12. The mask of claim 7 wherein the filter body further comprises an intermediate layer of filter media formed from expanded polytetrafluoroethylene (PTFE).

13. The mask of claim 7 wherein the filter body further comprises a first layer of bicomponent material disposed on one side of the intermediate layer of expanded polytetrafluoroethylene and a second layer of the same bicomponent material disposed on the opposite side of the layer of expanded polytetrafluoroethylene.

14. A disposable face mask comprising:

a filter body sized to fit over the mouth and nose of a wearer, the filter body having top and bottom edges with the top edge arranged to extend across the nose and cheeks of the wearer and the bottom edge arranged to extend under the chin of the wearer;

the filter body having a pair of lateral edges extending between the top edge and the bottom edge;

a flap attached to each lateral edge of the filter body and arranged to extend from the filter body;

the flaps formed from fluid impervious, resilient material;

first securing means and second securing means attached to respective flaps and arranged to extend generally about the head of the wearer, the first and second securing means cooperating with the respective flaps for urging the top edge and the bottom edge into tight engagement with the face of the wearer to prevent undesired fluid flow between the top edge and the bottom edge and the wearer'"'"'s face;

the flaps cooperating with their respective first securing means and second securing means to prevent undesired fluid flow between the respective sides of the filter body and the face of the wearer;

a first strip of material disposed within the filter body adjacent to and extending along the top edge for forming a fluid seal with the face of the wearer;

a second strip of material disposed within the filter body adjacent to and extending along the bottom edge for forming a fluid seal with the face of the wearer; and

the first strip of sealing material and the second strip of sealing material selected from the group consisting of thin plastic film, hydrogel, polyethylene and polypropylene.

15. The mask of claim 14, further comprising:

the first strip of sealing material extending partially from the opening; and

the second strip of sealing material extending partially from the opening.

16. A disposable face mask for covering portions of a wearer'"'"'s face including the nose and mouth of the wearer comprising:

at least one layer of material having a generally rectangular configuration;

a top edge extending across the nose and cheeks of the wearer'"'"'s face and a bottom edge extending under the chin of the wearer;

the face mask having an exterior surface and an interior surface with lateral sides extending between the top edge and the bottom edge;

a thin strip of flexible film attached to the interior surface of the face mask along the top edge, bottom edge and each lateral side edge to form a fluid barrier with adjacent portions of the wearer'"'"'s face; and

a layer of adhesive material disposed on each strip of thin, flexible film to allow the film to adhere to the adjacent portion of the wearer'"'"'s face.

17. A face mask comprising:

a filter body formed from material having a generally rectangular configuration and sized to fit over the mouth and nose of a wearer, the filter body having a top edge and bottom edge with the top edge arranged to extend across the nose and cheeks of the wearer and the bottom edge arranged to extend under the chin of the wearer;

the filter body having an exterior surface and an interior surface with a pair of lateral edges extending between the top edge and the bottom edge;

a flap attached to each lateral edge of the filter body and arranged to extend from the filter body;

a securing means attached to the respective flaps and arranged to extend generally about the head of the wearer, the securing means cooperating with the flaps for urging the top edge and the bottom edge into tight engagement with the wearer to prevent undesired fluid flow between the top edge and the bottom edge and the wearer'"'"'s face;

the flaps cooperating with the securing means to prevent undesired fluid flow between the respective lateral edges of the filter body and the face of the wearer;

the securing means formed in part from a continuous loop engaged with both flaps for gathering and compressing each flap into sealing contact with adjacent portions of the wearer'"'"'s face; and

thin strips of flexible film attaches respectively to the top edge and the bottom edge on the interior surface of the filter body to form a fluid barrier with adjacent portions of the wearer'"'"'s face.

18. The mask of claim 17 wherein the securing means further comprises the continuous loop formed from resilient material.

19. A face mask comprising:

a filter body formed from material having multiple pleats and sized to fit over the mouth and nose of a wearer, the filter body having a generally rectangular configuration with a periphery including top and bottom edges with the top edge arranged to extend across the nose and cheeks of the wearer, and the bottom edge arranged to extend under the chin of the wearer;

the periphery of the filter body further including a first lateral edge and a second lateral edge opposite from each other and extending between the top edge and the bottom edge;

an elongated malleable member disposed adjacent to the top edge to allow configuring the top edge to closely fit the contours of the nose and checks of the wearer;

a respective flap attached to each lateral edge of the filter body and arranged to extend from the filter body;

each flap formed from material and folded to define a generally U-shaped section;

a continuous loop of material disposed within the U-shaped section of both flaps and arranged to extend generally about the head of the wearer; and

the continuous loop cooperating with the flaps for urging at least a portion of the periphery of the filter body into engagement with adjacent portions of the face of the wearer to prevent undesired fluid flow between the filter body and the wearer'"'"'s face.

20. The mask of claim 19 further comprising:

a strip of sealing material disposed on an interior surface of the filter body adjacent to and extending along the top edge;

a second strip of sealing material disposed on the interior surface of the filter body adjacent to and extending along the bottom edge; and

the first sealing strip and the second sealing strip cooperating with the flaps and the continuous loop of material to form a fluid barrier between the periphery of the filter body and the face of the wearer.