GB2610832A

GB2610832A - A face mask

Info

Publication number: GB2610832A
Application number: GB2113239.4A
Authority: GB
Inventors: Martin Howard Karl
Original assignee: Air Filtration Solutions Ltd
Current assignee: Air Filtration Solutions Ltd
Priority date: 2021-09-16
Filing date: 2021-09-16
Publication date: 2023-03-22

Abstract

An FFP3 face mask 10 comprising a half face mask part 11 and at least one strap 12 to mount the half face mask part over a wearer’s nose and mouth, the half face mask part including a central shaped portion 13 to cover the wearer’s mouth, an upper portion 14 to bridge a wearer’s nose and the lower portion (15; figure 2) to abut a wearer’s chin when worn and a transparent window 16 in the central shaped portion, the transparent window hermetically sealed about its perimeter to the central shaped portion. The straps may be configured to extend about a rear part of the head, and the strap may be resilient. The face mask may have a layered construction formed from multiple layers (figure 10).

Description

A FACE MASK

Technical Field of the Invention

The present invention relates generally to the field of face masks. In particular, but not exclusively, the invention concerns an FFP3 face mask with a transparent portion.

Background to the Invention

Masks are worn to protect a wearer's lungs from hazardous airborne substances, including particulate materials, aerosols and smoke.

EU Regulation EN 149: 2001 governs face masks and uses the acronym 'FFP' to describe protection levels. 'FFP' stands for 'Filtering half Face Masks'.

The masks are split into 3 categories determined by their protection level: FFP1, FFP2 and FFP3 An FFP1 is the most basic of masks. They are usually used to protect during DIY tasks such as sanding, for example. This mask can protect against non-toxic, airborne particulate substances such as brick dust, cement, limestone, and pollen but it won't be enough protection if the substance is toxic -a higher level of protection would be needed An FFP2 mask offers more protection than an FFP] mask. The FFP2 mask was recommended by the World Health Organisation (WHO) during the outbreaks or SARS, corona virus and avian flu It offers protection from substances in the air such as lead dust, as well as aerosols and smoke An FFP3 offers the highest level of protection from breathing in hazardous substances in the environment. An FFP3 mask can protect from a variety of toxins, such as asbestos, bacteria, viruses and are often used by healthcare professionals when handling hazardous pharmaceutical chemicals.

Embodiments of the invention seek to at least partially overcome or ameliorate any one or more of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

Summary of the Invention

According to a first aspect of the invention there is provided an FFP3 face mask comprising a half face mask part and at least one strap to mount the half face mask part over a wearer's nose and mouth, the half face mask part including a central shaped portion to cover the wearer's mouth, an upper portion to bridge a wearer's nose and the lower portion to abut a wearer's chin when worn, and a transparent window in the central shaped portion, the transparent window hermetically sealed about its perimeter to the central shaped portion.

Providing an FFP3 mask with a transparent window in the central shaped portion will allow other people to see the wearer' s lips to allow lip reading or to better visualise facial expressions, which may otherwise be hidden by a mask, whilst the hermetic seal will direct airflow about the transparent window providing protection to the FFP3 level The FFP3 mask may be provided with any number of straps. The FFP3 mask may be provided with any type of straps.

In one form, two elongate straps may be provided, one upper strap and one lower strap. In another form, a single continuous loop strap may be provided.

A loop or sleeve attachment or mounting portion may be provided on either side of the half face mask part and one or more of the straps may engage with the loop or sleeve attachment or mounting portion.

A preferred form is the provision of one or more straps which extend about a rear part of the head of the wearer rather than over the ears of the wearer. This will result in a more secure mounting of the mask when worn.

The straps may have any cross-sectional shape. Examples of cross-sectional shape may be circular or rectangular.

The at least one strap may be resilient, with some deformation required to fit the mask to the wearer's head and the resilience of the at least one strap then acting to hold the mask relative to a wearer's face. Alternatively, the at least one strap may be length adjustable with a suitable mechanism such as a buckle provided to allow the length adjustability. A length adjustable strap may also be resilient The mask may have a valve to allow airflow into and out of the mask. If a valve is provided, the valve will typically be associated with a filter. The mask may be a non-valved mask.

The mask may be provided in a metal-free form, with all materials used being non-metallic.

The mask may be provided in a latex free form to minimise the risk of irritation of the wearer skin which can be caused in some wearers, due to the presence of latex.

The half face mask part may include a central shaped portion to cover a wearer's mouth. The central shaped portion will typically have a generally circular central part with a side wing or similar extending from each side of the central shaped part. The central shaped part need not be circular. The central shaped part may have an arcuate top edge. The central shaped part may have an arcuate bottom edge.

The provision of a side wing on each side of the central shaped part will preferably allow attachment of the at least one strap. As mentioned above, an attachment loop or sleeve or similar may be provided on each side wing. The attachment loop or sleeve may be provided at or adjacent to a rear end of each side wing. Typically, a single attachment loop or sleeve is provided Each of the side wings may be integrally formed with the central portion. The side wings and central portion may be formed from a single piece of material. Alternatively, the side wings can be separately formed and attached to the central portion.

The central shaped portion may be spaced from the wearer's mouth due to the shape of the central shaped portion and/or the provision of the upper portion and lower portions. The central shaped portion may be at least partially rigid in order to maintain space between the rear side of the half face mask part and the wearer's mouth. The central shaped portion may at least resist deformation to maintain space between the rear side of the half face mask part and the wearer's mouth.

The transparent window may be located in an opening provided in the half face mask part, particularly in the central shaped portion, to be positioned overlying the wearer's mouth. A shaped opening may be provided in the half face mask part. As mentioned above, the transparent window will normally be sealed to one or more other components of the half face mask part in order to achieve the FFP3 level.

An upper portion to bridge a wearer's nose may be provided. The upper portion will normally be shaped to bridge the wearer's nose and also abut an upper portion of the wearer's cheeks beneath their eyes. The upper portion may extend from a side wing across the upper side edge of the central shaped portion.

At least a part of the upper portion will be provided to conform to the shape of the wearer's face The upper portion may be at least partially rigid in order to maintain its shape in order to at least resist deformation.

A reinforced nose portion or bridge portion may be provided The nose portion or bridge portion may be moldable about the wearer's nose.

The upper portion will normally be attached to an upper side edge of the central shaped portion. The upper portion may be stitched to the upper side edge of the central shaped portion and/or the side wing portions. The upper portion may be formed in one piece with the central shaped portion but given that a preferred form of the upper portion and the central shaped portion is an at least partially rigid shaped portion, the upper portion and central shaped portion will typically be formed separately and attached together.

A rear edge of the upper portion will preferably abut the wearer's face to substantially seal against the wearer's face.

A lower portion to abut a wearer's chin and/or neck may be provided The lower portion will normally be shaped to abut a wearer's chin and/or neck and also abut a lower portion of the wearer's cheeks about their jawline. The lower portion may extend from a side wing across the lower side edge of the central shaped portion.

At least a part of the lower portion will be provided to conform to the shape of the wearer's face. The lower portion may be at least partially rigid in order to maintain its shape in order to at least resist deformation.

The lower portion will normally be attached to a lower side edge of the central shaped portion. The lower portion may be stitched to the lower side edge of the central shaped portion and/or the side wing portions. The lower portion may be formed in one piece with the central shaped portion but given that a preferred form of lower portion and the central shaped portion is an at least partially rigid, shaped portion, the lower portion and central shaped portion will typically be formed separately and attached together.

A rear edge of the lower portion will preferably abut the wearer's face to substantially seal against the wearer's face.

The half face mask part will normally have a layered construction formed from more than one layer. Any number of layers may be provided. Each layer may be provided in the layered construction to provide a specific function. Each layer may be manufactured from one or more particular materials in order to provide a specific function.

Each layer may have any thickness. Any material and combination of materials can be used, ranging from 10-150 GSM.

Each layer may have a desired shape and/or configuration. For example, at least some layers may be provided with side wing portions, and some may not. At least some layers may have an upper portion and/or a lower portion, and some may not.

An innermost layer may be formed to reduce irritation for the wearer. An outermost layer may be configured to resist damage or soiling as it is exposed to the elements. One or more layers may be configured as filter layers. One or more structural layers to provide shape and/or rigidity to the mask.

The transparent window may be provided between the innermost and outermost layers. An opening may be provided in all of the layers of the mask to allow visibility of a part of the wearer's face while the mask is being worn, through the transparent window.

One or more layers of filter materials may be sealed to the edges of the transparent window.

The transparent layer may be sealed about its periphery.

A hermetic seal may be formed about the transparent window so that airflow in/out of the mask is through the filter material or layer.

The transparent window may be shaped. In an embodiment, the transparent 5 window is substantially diamond shaped. The diamond shape may have rounded or arcuate apices.

The transparent layer is usually a single layer of transparent material thick.

In an embodiment, all of the layers provided in the half face mask part may have two side wing portions except the transparent window. An inner layer and an outer layer 10 may have upper and lower portions All layers may have a central opening for the transparent window.

The layers may be attached together, at least about their respective peripheries. Stitching may be used to attach the layers together, although other methods such as fusion, welding or adhesive could be used instead or in any combination.

The transparent window will normally be provided in the half face mask part to overlie a wearer's mouth when the mask is worn properly to allow third parties a view of the wearer's mouth in particular. The transparent window will normally be positioned by a combination of the upper and lower portions to locate the central shaped portion over the mouth of the wearer.

The transparent window may be provided in the mask between particular layers provided. For example, the transparent window may be positioned relative to at least one structural layer, The transparent window may be sandwiched between a pair of structural layers.

One or more layers of the central shaped portion may be sealed to the transparent window. All of the layers of the central shaped portion may be sealed to the transparent window.

Any sealing method may be used for example, fusion sealing, welding or adhesive.

Preferably, any filter layers provided are sealed to the transparent window, particularly about the peripheral edge of the transparent window so that airflow is through the filter layers.

In an embodiment, an inner layer of anti-irritant material is provided, then one or more filter layers, one or more structural layers, then the transparent window, then one or more structural layers, then one or more filter layers, and an outer layer to build the central shaped portion. An upper portion and a lower portion can be mounted to the inner layer and outer layer (and/or any other layer if desired).

In another embodiment, a mask with fewer layers may be provided with an inner layer of anti-irritant material provided, then one or more filter layers, then the transparent window, then one or more filterlayers, and an outerlayer to build the central shaped portion. An upper portion and a lower portion can be mounted to the inner layer and outer layer (and/or any other layer if desired) In still another embodiment, a mask with fewer layers may be provided with an inner layer of anti-irritant material provided, then one or more structural layers, then the transparent window, then one or more structural layers, and an outer layer to build the central shaped portion. An upper portion and a lower portion can be mounted to the inner layer and outer layer (and/or any other layer if desired).

In any of the configurations, a layer may have more than one purpose, for example a filter layer may also be a structural layer and vice versa. Any of the layers may be provided to specifically facilitate the sealing of the transparent window to one or more layers.

The layers are usually formed of one or more materials to enable the layer to perform the function(s).

Any layers apart from the transparent window may be formed from fibres, woven or otherwise formed into a sheet and then formed into the shape of the layer, Materials which may be used to form these layers include polypropylene, polyester, nylon, polyvinyl, microglass, needle felt, EPTFE membrane, olefin, cotton or other non-synthetic fibre.

Natural or synthetic fibres may be used.

The transparent window may be formed from a transparent plastic or substitute including PET, APET, Acrylic, PIVINIA, Amorphous Copolyester, Liquid silicone rubber, lonomer resin, Fluorinated ethylene propylene, Styrene, or ABS or similar.

The transparent window may be rigid, at least partially rigid or flexible.

Detailed Description of the Invention

In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 is an axonometric view of a face mask of an embodiment.

Figure 2 is a front view of the face mask illustrated in Figure 1, Figure 3 is a rear view of the face mask illustrated in Figure 1.

Figure 4 is a top view of the face mask illustrated in Figure 1.

Figure 5 is a bottom view of the face mask illustrated in Figure 1.

Figure 6 is a left side view of the face mask illustrated in Figure 1.

Figure 7 is a top view of the mask portion of a face mask of an embodiment with the straps removed.

Figure 8 is a sectional side view of the mask portion illustrated in Figure 7 along line A-A.

Figure 9 is a detailed view of the portion illustrated in Figure 8 and identified as 'B'.

Figure 10 is an exploded axonometric view of the mask portion illustrated in Figure 7.

Figure 11 is a top view of the mask portion of a face mask of a further embodiment with the straps removed.

Figure 12 is a sectional side view of the mask portion illustrated in Figure 11 along line C-C.

Figure 13 is a detailed view of the portion illustrated in Figure 12 and identified as Figure 14 is an exploded axonometric view of the mask portion illustrated in Figure 11.

With reference to the accompanying figures, an FFP3 face mask is provided.

The FFP3 face mask illustrated includes a half face mask part 11 and a strap 12 to mount the half face mask part 11 over a wearer's nose and mouth.

The half face mask part 11 includes a central shaped portion 13 to cover the wearer's mouth, an upper portion 14 to bridge a wearer's nose and the lower portion 15 to abut a wearer's chin when worn. A transparent window 16 is provided in the central shaped portion 13. The transparent window 16 is hermetically sealed about its perimeter to the central shaped portion 13.

In the illustrated form, a single continuous loop strap 12 is provided. An attachment or mounting sleeve 17 is provided on either side of the half face mask part 11 and the loop strap 12 is mounted through the sleeve 17. This forms an upper and lower strap part as shown in Figure 1 which extend about a rear part of the head of the wearer rather than over the ears of the wearer, which result in a more secure mounting of the mask when being worn The strap 12 may be resilient with some deformation required to fit the mask 10 to the wearers head and the resilience of the strap then acting to hold the mask 10 onto a wearer's face.

The central shaped portion 13 is generally arcuate in a central part with a side wing 18 extending from each side of the central shaped part 13. The central shaped part 13 need not be circular. As illustrated, the central shaped part 13 has an arcuate (convex) top edge and an arcuate (convex) bottom edge.

The provision of a side wing 18 on each side of the central shaped part 13 allows attachment of the strap 12 (usually positioned around the cheeks of the wearer) The sleeve 17 is provided at or adjacent to a rear end of each side wing 18 Each of the side wings 18 may be integrally formed with the central shaped portion 13. The side wings 18 and central shaped portion 13 of the illustrated mask 10 are formed from a single piece of material.

The central shaped portion 13 may be spaced from the wearer's mouth due to the shape of the central shaped portion 13 and/or the provision of the upper portion 14 and lower portion 15. The central shaped portion 13 may be at least partially rigid in order to maintain space between the rear side of the half face mask part 11 and the wearer's mouth. The central shaped portion 13 may at least resist deformation to maintain space between the rear side of the half face mask part 11 and the wearer's mouth.

The transparent window 16 is located in an opening provided in the half face mask part 11, particularly in the central shaped portion 13, to be positioned overlying the wearer's mouth A shaped opening may be provided in the half face mask part As mentioned above, the transparent window 16 will normally be sealed to one or more other components of the half face mask part I I in order to achieve the FFP3 level The upper portion 14 is normally shaped to bridge the wearer's nose and also abut an upper portion of the wearer's cheeks, beneath their eyes. The upper portion 14 of the mask illustrated, extends from each side wing 18 across the upper side edge of the central shaped portion 13 At least a part of the upper portion 14 will be provided to conform to the shape of the wearer's face. The upper portion 14 may be at least partially rigid in order to maintain its shape order to at least resist deformation.

A reinforced nose or bridge portion 19 may be provided. The nose or bridge portion 19 may be moldable about the wearer's nose once the mask has been donned.

The upper portion 14 will normally be attached to an upper side edge of the central shaped portion 13. The upper portion 14 may be stitched to the upper side edge of the central shaped portion 13 and/or the side wing portions 18. The upper portion 14 may be formed in one piece with the central shaped portion 13 but given that a preferred form of the upper portion 14 and the central shaped portion 13 is an at least partially rigid, shaped portion, the upper portion 14 and central shaped portion 13 will usually be formed separately and attached together.

A rear (upper) edge of the upper portion 14 will preferably abut the wearer's face to substantially seal against the wearer's face when the mask is worn properly.

The lower portion 15 will normally be shaped to abut a wearer's chin and also abut a lower portion of the wearer's cheeks about their jawline. The lower portion 15 also extends from each side wing 18 across the lower side edge of the central shaped portion 13.

At least a part of the lower portion 15 will be provided to conform to the shape of the wearer's face. The lower portion 15 may be at least partially rigid in order to maintain its shape order to at least resist deformation.

The lower portion 15 is attached to a lower side edge of the central shaped portion 13. The lower portion b may be stitched to the lower side edge of the central shaped portion 13 and/or the side wings 18. The lower portion 15 may be formed in one piece with the central shaped portion 13 but given that a preferred form of lower portion and the central shaped portion 13 is an at least partially rigid, shaped portion, the lower portion 15 and central shaped portion 13 will typically be formed separately and attached together.

A rear (lower) edge of the lower portion 15 will preferably abut the wearer's face to substantially seal against the wearer's face.

The half face mask part 11 will normally have a layered construction formed from more than one layer. Examples of this constructions are illustrated in Figures 7 to 14. Any number of layers may be provided. Each layer may be provided in the layered construction to provide a specific function Each layer may be manufactured from one or more particular materials in order to provide a specific function.

Each layer may have any shape and/or configuration. For example, at least some layers may be provided with side wing portions 18, and some may not. At least some layers, may have an upper portion 14 and/or a lower portion 15, and some may not.

The transparent window may be provided between the innermost and outermost layers. As shown in Figures 10 and 14 in particular, an opening may be provided in all of the layers of the mask 10 to allow visibility of a part of the wearer's face while the 10 mask is being worn, through the transparent window.

One or more layers of filter materials may be sealed to the edges of the transparent window 16. The transparent window 16 is usually sealed about its periphery. A hermetic seal may be formed about the transparent window 16 so that airflow in/out of the mask is through the filter material or layer.

The transparent window 16 of the illustrated mask is substantially diamond shaped. The diamond shape may have rounded or arcuate apices.

The transparent layer 16 of the illustrated mask is a single layer of transparent material thick.

In the mask illustrated in Figures 10 and 14, all of the layers provided in the half 20 face mask part 11 have two side wings 18 except the transparent window 16. An inner layer and an outer layer may have upper and lower portions. All layers may have a central opening for the transparent window.

The transparent window 16 will normally be provided in the half face mask part to overlie a wearer's mouth when the mask is worn properly to allow third parties a view of the wearer's mouth in particular. The transparent window will normally be positioned by a combination of the upper portion 14 and lower portion 15 to locate the central shaped portion 13 over the mouth of the wearer.

The transparent window 16 may be provided in the mask between particular layers provided. For example, the transparent window may be positioned relative to at least one structural layer. The transparent window may be sandwiched between a pair of structural layers One or more layers of the central shaped portion may be sealed to the transparent window. All of the layers of the central shaped portion may be sealed to the transparent window.

Preferably, any filter layers provided are sealed to the transparent window, particularly about the peripheral edge of the transparent window so that airflow is through the filter layers In the mask illustrated in Figures 7 to 10, an inner layer 20 of anti-irritant material is provided, then a pair of filter layers 21, 22, a structural layer 23, then the transparent window 16, then 1 structural layer 24, then a pair of filter layers 25, 26, and an outer layer 27, to build the central shaped portion 13. An upper portion 14 and a lower portion 15 can be mounted to the inner layer 20 (and/or any other layer if desired).

In the mask shown in Figures 11 to 14, a mask 10 with fewer layers may be provided with an inner layer 28 of anti-irritant material provided, then a combination filter/structural layer 29, then the transparent window 16, then a combination filter/structural layer 30, and an outer layer 31 to build the central shaped portion 13. An upper portion 14 and a lower portion 15 are mounted to the inner layer 28 (and/or any other layer if desired).

In any of the configurations, a layer may have more than one purpose, for example a filter layer may also be a structural layer and vice versa Any of the layers may be provided to specifically facilitate the sealing of the transparent window to one or more layers.

The layers are usually formed of one or more materials to enable the layer to perform the function(s) Any layers apart from the transparent window may be formed from fibres, woven or otherwise formed into a sheet and then formed into the shape of the layer.

Materials which may be used to form these layers include polypropylene, polyester, nylon, polyvinyl, microglass, needle felt, EPTFE membrane, olefin, cotton or other non-synthetic fibre.

Natural or synthetic fibres may be used.

The transparent window may be formed from a transparent plastic or substitute including PET, APET, Acrylic, PMMA, Amorphous CopoWester, Liquid silicone rubber, Ionomer resin, Fluorinated ethylene propylene, Styrene, or ABS or similar.

The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims

Claims

CLAIMSAn FFP3 face mask comprising a half face mask part and at least one strap to mount the half face mask part over a wearer's nose and mouth, the half face mask part including a central shaped portion to cover the wearer's mouth, an upper portion to bridge a wearer' s nose and the lower portion to abut a wearer' s chin when worn and a transparent window in the central shaped portion, the transparent window hermetically sealed about its perimeter to the central shaped portion.
2. An FFP3 face mask as claimed in claim 1 wherein the one or more straps are configured to extend about a rear part of the head of the wearer rather than over the ears of the wearer.
3. An FFP3 face mask as claimed in claim 1 or claim 2 wherein the at least one strap is resilient with some deformation required to fit the mask to the wearer' s head and the resilience of the at least one strap then acting to hold the mask relative to a wearer's face.
An FFP3 face mask as claimed in any one of the preceding claims wherein the central shaped part has an arcuate top edge.
An FFP3 face mask as claimed in any one of the preceding claims wherein the central shaped part has an arcuate bottom edge.
6. An FFP3 face mask as claimed in any one of the preceding claims wherein the central shaped part comprises a side wing on each side of the central shaped part configured to allow attachment of the at least one strap.An FFP3 face mask as claimed in claim 6 further comprising an attachment loop is provided on each side wing configured to allow attachment of the at least one strap An FFP3 face mask as claimed in claim 6 or claim 7 wherein each of the side wings is integrally formed with the central shaped portion.An FFP3 face mask as claimed in any one of the preceding claims wherein the central shaped portion is at least partially rigid in order to at least resist deformation to maintain space between a rear side of the half face mask part and the wearer's mouth.10. An FFP3 face mask as claimed in any one of the preceding claims wherein the transparent window is located in an opening provided in the central shaped portion to be positioned overlying the wearer's mouth.11. An FFP3 face mask as claimed in any one of the preceding claims wherein the upper portion is shaped to bridge the wearer's nose and also abut an upper portion of the wearer's cheeks beneath their eyes.12. An FFP3 face mask as claimed in any one of the preceding claims wherein the upper portion is at least partially rigid in order to maintain its shape order to at least resist deformation.13. An FFP3 face mask as claimed in any one of the preceding claims wherein the lower portion is shaped to abut a wearer's chin and also abut a lower portion of the wearer's cheeks about their jawline 14. An FFP3 face mask as claimed in any one of the preceding claims wherein the lower portion may be at least partially rigid in order to maintain its shape order to at least resist deformation 15. An FFP3 face mask as claimed in any one of the preceding claims wherein the half face mask part has a layered construction formed from more than one layer.16. An FFP3 face mask as claimed in claim 15 wherein each layer has a thickness, ranging from 10-150 GSM.17. An FFP3 face mask as claimed in claim 15 or claim 16 wherein at least some layers are provided with aside wing portion.18. An FFP3 face mask as claimed in any one of claims 15 to 17 wherein at least some layers have an upper portion and/or a lower portion 19. An FFP3 face mask as claimed in any one of claims 15 to 18 wherein an innermost layer is formed to reduce irritation for the wearer.20. An FFP3 face mask as claimed in any one of claims 15 to 19 wherein one or more layers is configured as a filter layer.21. An FFP3 face mask as claimed in any one of claims 15 to 20 wherein one or more layers is configured as a structural layer to provide shape and/or rigidity to the mask.22. An FFP3 face mask as claimed in any one of claims 15 to 21 wherein an opening is provided in all layers of the mask to allow visibility of a part of the wearer's face while the mask is being worn, through the transparent window.23. An FFP3 face mask as claimed in any one of claims 15 to 22 wherein one or more layers of filter material is sealed to the edges of the transparent window about its periphery.24. An FFP3 face mask as claimed in any one of claims 15 to 23 wherein the layers are attached together, at least about their respective peripheries.25. An FFP3 face mask as claimed in any one of claims 15 to 24 wherein he transparent window may be sandwiched between a pair of structural layers.