WO2015050693A1

WO2015050693A1 - Disposable hygiene mask

Info

Publication number: WO2015050693A1
Application number: PCT/US2014/055744
Authority: WO
Inventors: Francois Lustenberger
Original assignee: Honeywell International Inc.
Priority date: 2013-10-04
Filing date: 2014-09-16
Publication date: 2015-04-09

Abstract

A disposable hygiene mask (200) comprising a nonwoven filter material (202) operable to protect others from a patient's exhalation but incapable of serving as a sufficient filter for the patient, wherein the filter material (202) allows for sufficiently high inhalation with minimal breathing resistance.

Description

NEW DUST HYGIENE DISPOSABLE MASK

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No.

61/886,791 , filed on October 4, 2013, which is hereby incorporated by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

REFERENCE TO A MICROFICHE APPENDIX [0003] Not applicable.

BACKGROUND

[0004] Personal protection equipment (PPE), specifically disposable masks, may be required to conform to certain regulations during design and manufacture. However, some disposable face masks may be used for applications that do not require the masks to meet PPE regulations, such as when the mask is only meant to filter larger particles in the exhalation of a wearer. When designing disposable face masks, the user's ability and ease of breathing while wearing the mask may be considered, as well as the fit and the comfort of the user who may wear the mask. Disposable masks may comprise filtration media, which may be made of melt- blown fibers and/or micro glass material. Filtration by a mask is accomplished when particles in the air are trapped in the matrix of the fibers contained in the filtration media of the mask.

SUMMARY

[0005] Aspects of the disclosure may include embodiments of a disposable hygiene mask comprising: a nonwoven filter material operable to protect others from a patient's exhalation but incapable of serving as a sufficient filter for the patient; and at least one strap for securing the mask to a head of the patient, wherein the strap may be coupled to the nonwoven filter material, wherein: the nonwoven filter material may allows for sufficiently high inhalation airflow with minimal breathing resistance; the nonwoven filter material may exhibits a differential pressure across the mask of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask during inhalation; the nonwoven filter material may be operable to filter approximately 95% of liquid aerosols from the patient's exhaled breath; and the nonwoven filter material of the mask may be transparent with a luminance factor of less than about 40 percent measure on a red back face. In some embodiments, the nonwoven filter material of the mask may have a density between about 60 grams per square meter and about 150 grams per square meter. In some embodiments, the mask may comprise one of a flat fold mask and a molded mask.

[0006] Additional aspects of the disclosure may include embodiments of a disposable hygiene mask comprising: a nonwoven filter material operable to protect others from a patient's exhalation but incapable of serving as a sufficient filter for the patient, wherein the filter material may allow for sufficiently high inhalation airflow with minimal breathing resistance; and at least one strap for securing the mask to a head of the patient, wherein the strap may be coupled to the nonwoven filter material.

[0007] In some embodiments, the nonwoven filter material may exhibits a differential pressure across the mask between about 0.01 millibars and about 0.04 millibars when flowing 95 liters of air per minute through the mask during inhalation. In some embodiments, the nonwoven filter material may exhibits a differential pressure across the mask of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask during inhalation. In some embodiments, the nonwoven filter material may exhibits a differential pressure across the mask of less than about 0.07 millibars when flowing 160 liters of air per minute through the mask during exhalation. In some embodiments, the nonwoven filter material may be operable to filter approximately 95% of liquid aerosols from the patient's exhaled breath. In some embodiments, the nonwoven filter material may be operable to filter between about 90% and about 98% of liquid aerosols from the patient's exhaled breath. In some embodiments, the nonwoven filter material of the mask may be transparent with a luminance factor of less than about 40 percent measure on a red back face. In some embodiments, the nonwoven filter material of the mask may be transparent with a luminance factor of less than about 75 percent on a yellow back face. In some embodiments, the nonwoven filter material of the mask may have a density less than about 200 grams per square meter. In some embodiments, the nonwoven filter material of the mask may have a density less than about 80 grams per square meter. In some embodiments, the nonwoven filter material of the mask may have a density between about 60 grams per square meter and about 200 grams per square meter. In some embodiments, the mask may comprise a molded mask. In some embodiments, the mask may comprise a fiat fold mask.

[0008] Other aspects of the disclosure may include embodiments of a disposable hygiene mask comprising: a nonwoven filter material, wherein the nonwoven filter material of the mask may be transparent with a luminance factor of less than about 40 percent on a red back face; and at least one strap for securing the mask to a head of the patient, wherein the strap may be coupled to the nonwoven filter material. In some embodiments, the filter material may allow for sufficiently high inhalation airflow with minimal breathing resistance, and wherein the nonwoven filter material may exhibits a differential pressure across the mask of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask during inhalation. In some embodiments, the nonwoven filter material may have a density less than about 100 grams per square meter. In some embodiments, the nonwoven filter material may be operable to filter more than about 95% of liquid aerosols from the patient's exhaled breath. [0009] For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0010] FIGS. 1A-1B illustrate an exemplary disposable fiat fold face mask;

[0011 ] FIGS. 2A-2B illustrate an embodiment of a disposable flat fold face mask comprising a transparent mask material;

[0012] FIG. 3 illustrates an embodiment of a disposable molded face mask; and

[0013] FIG. 4 illustrates an embodiment of a disposable molded face mask comprising a transparent mask material.

DETAILED DESCRIPTION

[0014] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

[0015] The following brief definition of terms shall apply throughout the application:

[0016] The term "comprising" means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

[0017] The phrases "in one embodiment," "according to one embodiment," and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment); [0018] If the specification describes something as "exemplary" or an "example," it should be understood that refers to a non-exclusive example;

[0019] The terms "about" or approximately" or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field; and

[0020] If the specification states a component or feature "may," "can," "could," "should," "would," "preferably," "possibly," 'typically," "optionally," "for example," "often," or "might" (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

[0021 ] Embodiments relate generally to improved disposable masks for use in a hygiene sensitive environment, such as in the medical field, for example. The disposable masks may be designed to filter larger particles exhaled by a wearer of the mask, thereby protecting others (or products, such as medical devices or electrical components) from the breath of a user. In some embodiments, the masks may be used to prevent dust or other particles in the environment from reaching a wearer of the mask. In some embodiments, the masks may be molded, having a fixed shape. In other embodiments, the masks may be folded masks that can be folded flat but fit around a face of a user. In some embodiments, the masks may be at least partially transparent, allowing the user's face to be seen from outside the mask. This may be beneficial if the user of the mask is talking with another person, for example. Also, the masks may comprise low breathing resistance. Embodiments may also relate to methods of manufacturing the above described masks.

[0022] Most of the products in this product area are molded masks with a low efficiency filtering media or a basic shell. The price is a sensitive product parameter and it is preferred to manufacture using an automated line. The existing products proposed are poor for the end-user (bad breathability, no features, etc.)- The disposable masks area is moving from a molded market to a fiat fold masks. This invention is for both the molded mask market and the folded mask market. It is based on a unique layer which improves the breathability by using a different kind of nonwoven material from what is currently used in this market.

[0023] FIGS. 1A-1B illustrate an embodiment of a flat fold mask 100, comprising a nonwoven fabric material 102 and one or more head straps 104 operable to hold the mask 100 against the face of a wearer. The mask 100 of FIGS. 1 A- IB may be one of typical construction in the flat fold mask market

[0024] FIGS. 2A-2B illustrate an embodiment of a flat fold mask 200, wherein the nonwoven fabric 202 of the mask 200 comprises a transparent fabric. Therefore, the face 210 of a user (or the nose and mouth of a user) may be visible through the fabric 202 of the mask 200, allowing for better communication between the user and others. Additionally, the mask 200 may comprise one or more straps 204 operable to hold the mask 200 against the face 210 of a wearer. The mask 200 may comprise a disposable hygiene mask, which may be worn by medical patients or medical staff, for example. The transparency of the mask 200 may allow for better communication between a patient and medical personnel, for example. In some embodiments, the nonwoven filter material (or fabric) 202 may be operable to protect others from the patient's exhalation but may be incapable of serving a sufficient filter for the patient. In some embodiments, the mask 200 may provide improved breathability, with minimal breathing resistance through the nonwoven fabric material 202.

[0025] In some embodiments, the nonwoven fabric material 202 may exhibit a differential pressure across the mask of less than about 0.04 millibars when flowing approximately 95 liters of air per minute through the mask, wherein 95 liters of air per minute may represent the air flow during inhalation. In some embodiments, the nonwoven fabric material 202 may exhibit a differential pressure across the mask of between about 0.01 millibars and about 0.04 millibars when flowing approximately 95 liters of air per minute through the mask (during inhalation). In some embodiments, the nonwoven fabric material 202 may exhibit a differential pressure across the mask of less than about 0.07 millibars when flowing approximately 160 liters of air per minute through the mask, wherein 160 liters of air per minute may represent the air flow during exhalation.

[0026] Because of the density of the fibers of the nonwoven fabric material 202 and the proximity of the mask 200 to the wearer's (or patient's) face, the nonwoven material 202 may be operable to sufficiently filter particles (liquid aerosols) from the wearer's exhalations. In some embodiments, the nonwoven filter material may be operable to filter more than about 95% of liquid aerosols from the patient's exhaled breath. In some embodiments, the nonwoven filter material may be operable to filter between about 90% and about 98% of liquid aerosols from the patient's exhaled breath. The filter efficiency may be close to 95% penetration according to EN 149:2001 for liquid penetration.

[0027] In some embodiments, the nonwoven filter material 202 of the mask 200 may have a density between about 60 grams per square meter and about 150 grams per square meter. In some embodiments, the nonwoven filter material 202 of the mask 200 may have a density less than about 200 grams per square meter. In some embodiments, the nonwoven filter material 202 of the mask 200 may have a density less than about 80 grams per square meter.

[0028] In some embodiments, the transparency of the mask 200 may be measured by a luminance factor, which may comprise the ratio (or percentage) of the luminance of a surface or medium under specified condition of incidence, observation, and light source to the luminance of a lossless, perfectly diffusing surface or medium under the same conditions. Luminance factor may be considered as measuring the brightness or reflectance of a material. In some embodiments, to determine the transparency, the nonwoven material 202 of the mask 200 may be placed on a colored back face, such as a red back face or a yellow back face, and the luminance factor of the nonwoven material 202 of the mask 200 (on the back face) may be compared to the luminance factor of the blank red back face. In some embodiments, a red back face may comprise a luminance factor of approximately 18.75%, and the mask 200 placed on the red back face may comprise a luminance factor of approximately 34.54%. By comparison, a typical, non-transparent mask 100 placed on the red back face may comprise a luminance factor of approximately 86.02%. Thus, by comparing the luminance factor of the typical mask 100 and the transparent mask 200, it may be seen that the typical mask 100 may be brighter or have more reflectance than the transparent mask 200, wherein the luminance of the transparent mask 200 may be closer to the luminance of the blank red back face.

[0029] A similar comparison may be made when the luminance factor is measured on a yellow back face. In some embodiments, the yellow back face may comprise a luminance factor of approximately 68.61%, and the transparent mask 200 placed on the yellow back face may comprise a luminance factor of approximately 71.04%. By comparison, a typical, non- transparent, mask 100 placed on the yellow back face may comprise a luminance factor of approximately 88.41%. Thus, by comparing the luminance factor of the typical mask 100 and the transparent mask 200, it may be seen that the typical mask 100 may be brighter or have more reflectance than the transparent mask 200, wherein the luminance of the transparent mask 200 may be closer to the luminance of the blank yellow back face.

[0030] FIG. 3 illustrate an embodiment of a molded face mask 300, comprising a nonwoven fabric material 302 and one or more head straps 304 operable to hold the mask 300 against the face of a wearer. The mask 300 of FIG. 3 may be one of typical construction in the molded mask market.

[0031 ] FIG. 4 illustrates an embodiment of a molded face mask 400, wherein the nonwoven fabric 402 of the mask 400 comprises a transparent fabric, allowing for better communication between the user and others. Therefore, the face 410 of a user (or the nose and mouth of a user) may be visible through the fabric 402 of the mask 400. In some embodiments, the transparency of the mask 400 may be determined as described above. Additionally, the mask 400 may comprise one or more straps 404 operable to hold the mask 400 against the face 410 of a wearer. The mask 400 may comprise a disposable hygiene mask, which may be worn by medical patients for example. The transparency of the mask 400 may allow for better communication between a patient and medical personnel, for example. In some embodiments, the nonwoven filter material (or fabric) 402 may be operable to protect others from the patient's exhalation but may be incapable of serving a sufficient filter for the patient In some embodiments, the mask 400 may provide improved breathability, with minimal breathing resistance through the nonwoven fabric material 402.

[0032] In some embodiments, the nonwoven fabric material 402 may exhibit a differential pressure across the mask of less than about 0.04 millibars when flowing approximately 95 liters of air per minute through the mask, wherein 95 liters of air per minute may represent the air flow during inhalation. In some embodiments, the nonwoven fabric material 402 may exhibit a differential pressure across the mask of between about 0.01 millibars and about 0.04 millibars when flowing approximately 95 liters of air per minute through the mask (during inhalation). In some embodiments, the nonwoven fabric material 402 may exhibit a differential pressure across the mask of less than about 0.07 millibars when flowing approximately 160 liters of air per minute through the mask, wherein 160 liters of air per minute may represent the air flow during exhalation. In some embodiments, the nonwoven fabric material 402 may exhibit a differential pressure across the mask of less than about 0.14 millibars when flowing approximately 160 liters of air per minute through the mask (during exhalation).

[0033] Because of the density of the fibers of the nonwoven fabric material 402 and the proximity of the mask 400 to the wearer's (or patient's) face, the nonwoven material 402 may be operable to sufficiently filter particles (such as solid or liquid aerosols) from the wearer's exhalations. In some embodiments, the nonwoven filter material 402 may be operable to filter more than about 95% of liquid aerosols from the patient's exhaled breath. In some embodiments, the nonwoven filter material 402 may be operable to filter between about 90% and about 98% of liquid aerosols from the patient's exhaled breath. In some embodiments, the nonwoven filter material 402 may be operable to filter more than about 97% of liquid aerosols from the patient's exhaled breath. The filter efficiency may be close to 95% penetration according to E 149:2001 for liquid penetration.

[0034] In some embodiments, the nonwoven filter material 402 of the mask 400 may have a density between about 60 grams per square meter and about 150 grams per square meter. In some embodiments, the nonwoven filter material 402 of the mask 200 may have a density less than about 400 grams per square meter.

[0035] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

[0036] Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

CLAIMS What is claimed is:

1. A disposable hygiene mask (200) comprising:

a nonwoven filter material (202) operable to protect others from a patient's exhalation but incapable of serving as a sufficient filter for the patient; and

at least one strap (204) for securing the mask to a head of the patient, wherein the strap (204) is coupled to the nonwoven filter material (202),

wherein:

the nonwoven filter material (202) allows for sufficiently high inhalation airflow with minimal breathing resistance;

the nonwoven filter material (202) exhibits a differential pressure across the mask (200) of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask during inhalation;

the nonwoven filter material (202) is operable to filter approximately 95% of liquid aerosols from the patient's exhaled breath; and

the nonwoven filter material (202) of the mask (200) is transparent with a luminance factor of less than about 40 percent measure on a red back face.

2. The mask of claim 1, wherein the nonwoven filter material (202) of the mask (200) has a density between about 60 grams per square meter and about 150 grams per square meter.

3. A disposable hygiene mask (200) comprising:

a nonwoven filter material (202) operable to protect others from a patient's exhalation but incapable of serving as a sufficient filter for the patient, wherein the filter material (202) allows for sufficiently high inhalation airflow with minimal breathing resistance; and

at least one strap (204) for securing the mask (200) to a head of the patient, wherein the strap (204) is coupled to the nonwoven filter material (202).

4. The mask of claim 3, wherein the nonwoven filter material (202) exhibits a differential pressure across the mask (200) of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask (200) during inhalation.

5. The mask of claim 3, wherein the nonwoven filter material (202) exhibits a differential pressure across the mask (200) of less than about 0.07 millibars when flowing 160 liters of air per minute through the mask (200) during exhalation.

6. The mask of claim 3, wherein the nonwoven filter material (202) is operable to filter approximately 95% of liquid aerosols from the patient's exhaled breath.

7. The mask of claim 3, wherein the nonwoven filter material (202) of the mask (200) is transparent with a luminance factor of less than about 40 percent measure on a red back face.

8. The mask of claim 3, wherein the nonwoven filter material (202) of the mask (200) is transparent with a luminance factor of less than about 75 percent on a yellow back face.

9. The mask of claim 3, wherein the nonwoven filter material (202) of the mask (200) has a density less man about 200 grams per square meter.

10. The mask of claim 3, wherein the nonwoven filter material (202) of the mask (200) has a density between about 60 grams per square meter and about 200 grams per square meter.

11. The mask of claim 3, wherein the mask (200) comprises one of a molded mask (400) and a flat fold mask (200).

12. A disposable hygiene mask (200) comprising:

a nonwoven filter material (202), wherein the nonwoven filter material (202) of the mask (200) is transparent with a luminance factor of less than about 40 percent on a red back face; and

13. The mask of claim 12, wherein the filter material (202) allows for sufficiently high inhalation airflow with minimal breathing resistance, and wherein the nonwoven filter material (202) exhibits a differential pressure across the mask (200) of less than about 0.04 millibars when flowing 95 liters of air per minute through the mask (200) during inhalation.

14. The mask of claim 12, wherein the nonwoven filter material (202) has a density less than about 100 grams per square meter.

15. The mask of claim 12, wherein the nonwoven filter material (202) is operable to filter approximately 95% of liquid aerosols from the patient's exhaled breath.