Filter mask

• US 7,036,507 B2
• Filed: 12/18/2003
• Issued: 05/02/2006
• Est. Priority Date: 12/18/2003
• Status: Active Grant

• Current Assignee: Alpha Pro Tech, Inc. (Alpha Pro Tech Ltd.)
• Original Assignee: Alpha Pro Tech, Inc. (Alpha Pro Tech Ltd.)
• Inventors: Jensen, John W.
• Primary Examiner(s): Bennett, Henry
• Assistant Examiner(s): Bunin, Andrew
• Application Number:
  US10/739,245
• Publication Number:
  US 20050133034A1
• Time in Patent Office: 866 Days
• Field of Search: 128/205.25, 128/205.29, 128/206.12, 128/206.13, 128/206.19
• US Class Current: 128/206.19
• CPC Class Codes: A41D 13/1115 with a horizontal pleated pocket
• CPC Class Codes: A62B 23/025 the filter having substantially the shape of a mask surgical face masks A41D13/11

Abstract

The invention provides a filter mask for filtering air inhaled and exhaled from the mouth and nostrils while providing a positive facial lock at all edges of the mask. The filter mask has upper and lower edges which are provided with malleable stiffeners for conforming to the shape of the wearer'"'"'s nose and cheek area and the lower jaw and chin area, respectively. The material of the filter mask is folded to have an omega pleat for forming a breathing chamber and a secondary pleat for assisting in securing the mask to the lower jaw and chin area. A pair of headbands are used to hold the mask on the head. The peripheral edges of the mask are bound. The mask provides excellent filtration since the positive facial lock around all edges of the mask substantially prevents air from leaking between the mask and the face.

Claims

1. A filter mask comprising:

filter material having an inner surface to be worn against a wearer'"'"'s face, and an outer surface, said filter material comprising pleated means for folding and unfolding said filter material such that when folded said filter materials assumes an essentially flat storage configuration having upper, lower and side edges and such that when unfolded said filter material forms a mask adapted for placement on the wearer'"'"'s head so as to cover the nose and mouth of the wearer, said pleated means comprising an omega pleat provided proximate to said upper edge in said essentially flat storage configuration and a secondary pleat provided between said omega pleat and said lower edge in said essentially flat storage configuration, said omega pleat providing a breathing chamber when unfolded, said secondary pleat providing a pocket adapted to fit over a chin of the wearer when unfolded, said secondary pleat comprises a first fold and a second fold; and

means for securing said filter material to a head of the wearer.

2. A filter mask as defined in claim 1, further comprising a malleable stiffening member which is configured to conform said filter material to a nose and cheek area of the face of the wearer, said malleable stiffening member being attached to said filter material proximate to said upper edge thereof.

3. A filter mask as defined in claim 1, further comprising a malleable stiffening member which is configured to conform said filter material to a chin and jaw area of the face of the wearer, said malleable stiffening member being attached to said filter material proximate to said lower edge thereof.

4. A filter mask as defined in claim 1, wherein said omega pleat comprises a first fold, a second fold, a third fold and a fourth fold, said first fold of said omega pleat folds said filter material such that said inner surface of said filter material is folded back onto itself toward said lower edge of said filter material, said second fold of said omega pleat fold said filter material such tat said outer surface of said filter material is folded back onto itself toward said lower edge of said filter material, said third fold of said omega pleat folds said filter material such that said outer surface of said filter material is folded back onto itself toward said upper edge of said filter material, said fourth fold of said omega pleat folds said filter material such that said inner surface of said filter material is folded back onto itself toward said lower edge of said filter material.

5. A filter mask as defined in claim 4, wherein a stiffening member is operatively associated with said second fold of said omega pleat.

6. A filter mask as defined in claim 4, wherein a stiffening member is operatively associated with said third fold of said omega pleat.

9. A filter mask as defined in claim 1, wherein said means for securing said filter mask comprises a pair of headbands which are secured to said filter material.

10. A filter mask as defined in claim 9, wherein said headbands are formed of an elastic material.

11. A filter mask as defined in claim 1, wherein said filter material comprises an outer layer, an inner layer and a middle layer of a material having a high filtration efficiency.

12. A filter mask as defined in claim 1, wherein said upper and lower edges of said filter material are bound by heat activated tape.

13. A filter mask as defined in claim 1, wherein said omega and secondary pleats are bound in place by heat activated tape.

7. A filter comprising:

filter material having an inner surface to be worn against a wearer'"'"'s face, and an outer surface, said filter material comprising pleated means for folding and unfolding said filter material such that when folded said filter material assumes an essentially flat storage configuration having upper, lower and side edges and such that when unfolded said filter material forms a mask adapted for placement on the wearer'"'"'s head so as to cover the nose and mouth of the wearer, said pleated means comprising am omega pleat provided proximate to said upper edge in said essentially flat storage configuration and a secondary pleat provided between said omega pleat and said lower edge in said essentially flat storage configuration, said omega pleat providing a breathing chamber when unfolded, said secondary pleat providing a pocket adapted to fit over a chin of the wearer when unfolded, wherein said omega pleat comprises a first fold, a second fold, a third fold and a fourth fold, said first fold of said omega pleat folds said filter material such that said inner surface of said filter material is folded back onto itself toward said lower edge of said filter material, said second fold of said omega pleat folds said filter material such that said outer surface of said filter material is folded back onto itself toward said lower edge of said filter material, said third fold of said omega pleat folds said filter material such that said outer surface of said filter material is folded back onto itself toward said upper edge of said filter material, said fourth fold of said omega pleat folds said filter material such that said inner surface of said filter material is folded back onto itself toward said lower edge of said filter material, said secondary pleat comprises a first fold and a second fold; and

means for securing said filter material to a head of the wearer.

8. A filter mask as defined in claim 7, wherein said first fold of said secondary pleat folds said filter material such that said outer surface of said filter material is folded back onto itself toward said lower edge of said filter material, said second fold of said secondary pleat folds said filter material such that said inner surface of said filter material is folded back onto itself toward said lower edge of said filter material.

14. A filter mask which, when folded, assumes an essentially flat storage configuration and which, when unfolded, assumes an installed configuration for covering the nostrils and mouth of a wearer, comprising:

flexible filtering means for filtering inhaled and exhaled air comprising;

inner and outer surfaces, said inner surface to be positioned against the wearer'"'"'s face when said mask is in said installed configuration,

upper and lower edges in said essentially flat storage condition, said upper edge to be provided proximate to the wearer'"'"'s nose and cheeks when said mask is in said installed configuration, said lower edge to be provided proximate to the wearer'"'"'s jaw and chin when said mask is in said installed configuration,

an omega pleat provided proximate to said upper edge when said mask is in said essentially flat storage configuration, said omega pleat providing a breathing chamber when said mask is in said installed configuration,

a secondary pleat provided between said omega pleat and said lower edge when said mask is in said essentially flat storage configuration, said secondary pleat providing a pocket adapted to fit over the chin of the wearer when said mask is in said installed configuration, said secondary pleat comprises a first fold and a second fold; and

means for securing said flexible filtering means to the head of the wearer.

15. A filter in ask as defined in claim 14, further comprising a malleable stiffening member which is configured to conform said flexible filtering means to a nose and cheek area of the face of the wearer, said malleable stiffening ember being attached to said flexible filtering means proximate to said upper edge thereof.

16. A filter mask as defined in claim 14, further comprising a malleable stiffening member which is configured to conform said flexible filtering means to a chin and jaw area of the face of the wearer, said malleable stiffening member being attached to said flexible filtering means proximate to said lower edge thereof.

17. A filter mask as defined in claim 14, wherein said omega pleat comprises a first fold, a second fold, a third fold and a fourth fold, said first fold of said omega pleat folds said flexible filtering means such that said inner surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means, said second fold of said omega pleat folds said flexible filtering means such the said outer surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means, said third fold of said omega pleat folds said flexible filtering means such that said outer surface of said flexible filtering means is folded back onto itself toward said upper edge of said flexible filtering means, said fourth fold of said omega pleat folds said flexible filtering means such that said inner surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means.

18. A filter mask as defined in claim 17, wherein a stiffening member is operatively associated with said second fold of said omega pleat.

19. A filter mask as defined in claim 17, wherein a stiffening member is operatively associated with said third fold of said omega pleat.

22. A filter mask as defined in claim 14, wherein said means for securing said filter mask comprises a pair of headbands which are secured to said flexible filtering means.

23. A filter mask as defined in claim 22, wherein said headbands are formed of an elastic material.

24. A filter mask as defined in claim 14, wherein said flexible filtering means comprises an outer layer, an inner layer and a middle layer of a material having a high filtration efficiency.

25. A filter mask as defined in claim 14, wherein raid upper and lower edges of said filter material are bound by heat activated tape.

26. A filter mask as defined in claim 14, wherein said omega and secondary pleats are bound in place by heat activated tape.

20. A filter mask which, when folded, assumes an essentially flat storage configuration and which, when unfolded, assumes an installed configuration for covering the nostrils and mouth of a wearer, comprising:

flexible filtering means for filtering inhaled and exhaled air comprising;

inner and outer surfaces, said inner surface to be positioned against the wearer'"'"'s face when said mask is in said installed configuration,

upper and lower edges in said essentially flat storage condition, said upper edge to be provided proximate to the wearer'"'"'s nose and cheeks when said mask is in said installed configuration, said lower edge to be provided proximate to the wearer'"'"'s jaw and chin when said mask is in said installed configuration,

an omega pleat provided proximate to said upper edge when said mask is in said essentially flat storage configuration, said omega pleat providing a breathing chamber, when said mask is in said installed configuration, said omega pleat comprises a first fold, a second fold, a third fold and a third fold, said first fold of said omega pleat folds said flexible filtering means such that said inner surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means, said second fold of said omega pleat folds said flexible filtering means such that said outer surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means, said third fold of said omega pleat folds said flexible filtering means such that said outer surface of said flexible filtering means is folded back onto itself toward said upper edge of said flexible filtering means, said fourth fold of said omega pleat folds said flexible filtering means such that said inner surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means,

a secondary pleat provided between said omega pleat and said lower edge when said mask is in said essentially flat storage configuration, said secondary pleat providing a pocket adapted to fit over the chin of the wearer when said mask is in said installed configuration, said secondary pleat comprises a first fold and a second fold; and

means for securing said flexible filtering means to the head of the wearer.

21. A filter mask as defined in claim 20, wherein said first fold of said secondary pleat folds said flexible filtering means such that said outer surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means, said second fold of said secondary pleat folds said flexible filtering means such that said inner surface of said flexible filtering means is folded back onto itself toward said lower edge of said flexible filtering means.

27. A filter mask comprising:

filter material having an inner surface to be worn against a wearer'"'"'s face, and an outer surface, said filter material comprising pleated means for folding and unfolding said filter material such that when folded said filter materials assumes an essentially flat storage configuration having upper, lower and side edges and such that when unfolded said filter material forms a mask adapted for placement on the wearer'"'"'s head so as to cover the nose and mouth of the wearer, said pleated means comprising an omega pleat provided proximate to said upper edge and a secondary pleat provided between said omega pleat and said lower edge, said omega pleat providing a breathing chamber when unfolded, said secondary pleat providing a pocket adapted to fit over a chin of the wearer when unfolded, said secondary pleat comprises a first fold and a second fold; and

means for securing said filter material to a head of the wearer.

28. A filter mask which, when folded, assumes an essentially flat storage configuration and which, when unfolded, assumes an installed configuration for covering the nostrils and month of a wearer, comprising:

flexible filtering means for filtering inhaled and exhaled air comprising;

inner and outer surfaces, said inner surface to be positioned against the wearer'"'"'s face when said mask is worn by the wearer,

upper and lower edges, said upper edge to be provided proximate to the wearer'"'"'s nose and cheeks when said mask is worn by the wearer, said lower edge to be provided proximate to the wearer'"'"'s jaw and chin when said mask is worn by the wearer,

an omega pleat provided proximate to said upper edge, said omega pleat providing a breathing chamber when said mask is worn by the wearer,

a secondary pleat provided between said omega pleat and said lower edge, said secondary pleat providing a pocket adapted to fit over the chin of the wearer when said mask is worn by the wearer, said secondary pleat comprises a first fold and a second fold; and

means for securing said flexible filtering means to the head of the wearer.