WO2023033705A1

WO2023033705A1 - A face mask

Info

Publication number: WO2023033705A1
Application number: PCT/SE2022/050783
Authority: WO
Inventors: Stefan Witte
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-09-02
Filing date: 2022-09-02
Publication date: 2023-03-09
Anticipated expiration: 2024-03-02

Abstract

The present disclosure generally relates to a face mask, and particularly to a face mask comprising at least a first air flow channel adapted to allow the user to both draw and subsequently exhale respiration air from a position downwards or backwards relative to the mouth of the user.

Description

A FACE MASK

TECHNICAL FIELD

BACKGROUND

The global Covid 19 pandemic clearly showed that most countries were not sufficiently prepared to stop the spread of an airborne respiratory infection. Various strategies were implemented pending the development of vaccines including lockdown, social distancing and - in varying degrees - the use of facial protection (“masks”). The SARS-CoV- 2 virus has shown the ability to mutate frequently, and it appears to adapt to become more infectious over time. It is likely that new and different variants of the virus will continue to cause Covid 19 to be an “ongoing” or seasonal infection for many years. There is also the risk that other, known or currently unknown, airborne viruses or bacteria may cause even more serious infections.

On the positive side, the Covid pandemic demonstrated the considerable advances that have been made in rapidly developing vaccines. The key to preventing high mortality rates and severe illness caused by future potential airborne infections will thus likely be the ability to again develop new vaccines rapidly. Such vaccines will however likely not be available until after at least several months and the delaying strategies used in the Covid pandemic will need to be applied again. Lockdown is however a harsh and economically drastic method and social distancing, on its own, likely insufficient. Respiratory protection in the form of obligatory general use of face masks will thus most likely be a crucial part of any future infection delaying/protection strategy. During the pandemic, the World Health Organization (WHO) recommended the general population to always wear a face mask in the immediate proximity of other people.

During the Covid pandemic there has been a development from not wearing any face mask at all to using a simple certified or non-certified “IIR” type of mask, and then towards using Personal Protection Equipment (PPE) for instance Filtering Facepiece Respirators such as FFP-2 and FFP-3 grade masks. In reviewing the working environment for people who wear masks during longer periods, such as for instance doctors, nurses and care staff, it has become apparent that there is need to further improve generally used face masks/respirators to improve both safety and comfort/wearability.

For example, for traditional face masks/respirators leakage can occur allowing contaminated air to be inhaled and/or exhaled by the wearer thereby risking infection of the wearer and/or the patient. Additionally, filtration takes place across the entire membrane surface of the mask and inhalation/exhalation takes place straight ahead through the same membrane. A large concentration of virus and bacteria is thus accumulated in the mask. The greatest accumulation of virus and bacteria in the mask takes place in front of the mouth. Virus collected in the mask, during the entire time that the wearer has used the mask can be released when exhaling and becomes a danger for those nearby not wearing a mask.

Skin problems may also appear when moisture appears in the masks, which in turn can result in rashes and eczema.

Additionally, a contributing cause of fatigue for e.g. healthcare professionals using masks together with a visor may be that you inhale "old" air . The carbon dioxide content increases during use and can lead to increased fatigue because you are constantly inhaling your own exhaled air, even if some air comes in from the side.

Still further, there is a risk of spreading infection due to the wearer touching the contaminated outside surface of the mask when fitting/removing/adjusting the mask and then touching his/her face with contaminated fingers.

In some prior-art implementations, masks can be equipped with exhalation valves to facilitate the wearer's breathing. Most often these valves are not equipped with any filtration and unfiltered exhaled air will flow out in the direction of the patient. Even if the valve is equipped with a filter the valve may malfunction which will also lead to inhaled and exhaled air flowing freely through the valve. In both case the person wearing the mask and the patient can then be exposed to contaminated air.

Another general problem with prior-art masks is the issue with potential leakage. That is, in order to obtain a tight fit of the mask, and thereby reduce air leakage, it may be necessary for the mask to be pressed quite firmly against the face. Skin damage from the edges of the masks can become a problem and cause abrasion.

Several of the issues described above are also apparent in masks used in industrial applications where the mask is used to protect the wearer against other kinds of airborne particles. An example of a mask trying to overcome the above listed general problems is presented in US20200121005A1. In US20200121005A1, there is specifically presented a mask including a housing defining an inner layer, an outer layer, and a volume in between, a mouth aperture to be disposed about a mouth of a user, a side aperture to allow fluid flow into and out of the housing, an oral fluid pathway extending from the mouth aperture to the side aperture, and a nasal aperture to be disposed adjacent to nostrils of the user. The mask also includes a nasal channel extending from the nasal aperture and to a nasal exit aperture. The housing is configured to route fluid flow received at the mouth aperture distally through the oral fluid pathway, and fluid flow received at the side aperture proximally through the oral fluid pathway. The nasal channel is configured to route fluid flow received at the nasal aperture distally through the nasal fluid pathway.

Even though the solution presented in US20200121005A1 generally provides some advantages as compared to general prior-art masks, the desire to “transport” air in the volume between the inner and outer layer makes the mask highly complicated. That is, it will be necessary to make the mask sturdy enough to allow the user to both draw and subsequently exhale respiration air. Such sturdiness of the mask will generally result in a risk for mask leakage. Additionally, the sturdiness of the mask will complicate manufacturing of the mask, thus making the final mask too expensive for general use.

Accordingly, a need exists for a novel type of face mask, further reducing the risk of transferring infectious bacteria, virus and the like between users and people in close proximity while at the same time being possible to manufacture at a low price, making it safe and easily accessible for an end user.

SUMMARY

In view of the above-mentioned need, a general object of the present disclosure is to provide an improved mask which at least to some extent provides further improvements in relation to prior-art.

According to an aspect of the present disclosure, there is provided a face mask, comprising a body portion configured to be placed over a mouth and at least part of a nose of a user, the body portion being impermeable to air at an area corresponding to the mouth and the nose of the user, and a fastening member attached to the body portion or the air channels and configured for retaining the body portion onto the face of the user, wherein the body portion comprises a first and a second air flow channel arranged as an integrated part of the body part on a left and a right-hand side, respectively, of the user’s face, wherein each of the first and the second air flow channel is adapted to allow the user to both draw and subsequently exhale respiration air, and the first and the second air flow channel are each provide with an external opening that is arranged to face downwards or backwards relative to the mouth of the user, wherein the first and the second air flow channel are permeable to air at the external openings.

By means of the face mask it is made possible to direct the air that is drawn and subsequently exhaled by the user, due to the fact that the body portion is impermeable to air in a forward direction as compared to a face of the user in combination with that the air flow channel has been arranged to face downwards or backwards relative to the mouth of the user, where the openings are permeable to air. This implementation could be compared to the classic approach of breathing “through” a breathable membrane, where the air is drawn and subsequently exhaled by the user straight in front of the mouth of the user.

Conversely to prior-art, an implementation in line with the present disclosure will assure that no unwanted e.g. respiratory particles that are generated by the end user are transmitted in a forward direction where possibly another person is located. Rather, air being exhaled by the user will be directed downwards backwards relative to the mouth of the user. An advantage following the implementation is thus that possible respiratory particles typically will be refrained from reaching a facial area of a person directly in front of the user.

An advantage following when using the mask according to the present disclosure includes for example the fact that, when wearing a visor, air exhaled by the user is less likely to trapped inside the visor and will therefore not be inhaled again. This should reduce the carbon dioxide level in the mask.

Additionally, in case a user of the mask is wearing glasses, these will not fog up so easily as when using prior-art masks. This is specifically achieved by means of the air flow channels that are arranged to ensure that the air being exhaled by the user is expelled adjacently to the ears of the user rather than through the mask. That is, in a prior-art solution the warm exhaled air will generally tend to propagate upwards and towards glasses, if worn by the user.

In line with the present disclosure, the face of the user will function as a portion of the air flow channels (first and second) that are provided to direct the drawn/expelled air to/from the mouth and nose of the user to/from the external openings. An advantage with such a feature is that the mask may be manufactured in a less complicated manner as compared to prior-art solutions, relying on fully enclosed air flow channels. An additional advantage is that the face mask may be more generic in its presence, still ensuring that the face mask tightly follows the face of the user. Such a feature has been identified as important to ensure a non-leaking mask.

Further features of, and advantages with, the present disclosure will become apparent when studying the appended claims and the following description. The skilled addressee realize that different features of the present disclosure may be combined to create embodiments other than those described in the following, without departing from the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The various aspects of the present disclosure, including its particular features and advantages, will be readily understood from the following detailed description and the accompanying drawings, in which:

Fig. 1 conceptually illustrates a face mask according to the present disclosure,

Fig. 2 presents an alternative implementation of the face mask further comprising a face shield,

Figs. 3 A and 3B show one further possible embodiment of the face mask according to the present disclosure, and

Figs. 4A and 4B show a still further possible embodiment of the face mask according to the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the present disclosure are shown. This present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the present disclosure to the skilled addressee. Like reference characters refer to like elements throughout.

In Fig. 1 there is conceptually presented a face mask 100. The face mask 100 comprises a body portion 102 configured to be placed over a mouth and at least part of a nose of a user. The body portion is impermeable to air, meaning that air will not be drawn through the body portion when the user is breathing.

Rather, in accordance to the present disclosure the air drawn and exhaled by the user will be directed through one or a plurality of air flow channels 104. The implementation as shown in Fig. 1 comprises a first 104 and a second air flow channel, where each of the air flow channels have an external opening 106 in a vicinity of an ear of the user. When breathing, the air will be drawn and exhaled through the air flow channels and in/out of the surrounding environment at the external openings 106. The external openings 106 are in accordance with the present disclosure as shown in Fig. 1 arranged to direct the airflow (in and out) in a downwards or backwards direction relative to the mouth of the user.

As shown in Fig. 1, the face mask 100 further comprises a fastening member, in the form of a strap 110, attached to the body portion 102 and provided for retaining the body portion 102 onto the face of the user. The fastening member may also or instead be attached to the air flow channels.

The mask 100 preferably comprises a sealing member adapted to seal the body portion 102 to the face of the user. The sealing member (not explicitly illustrated in Fig. 1), may for example include a foam element, possibly glued to an inside of the body portion 102.

The face mask 100 is further preferably configured in such a manner that an inside surface or structure of the body portion 102 maximizes a direction of an air flow through the first air flow channel. This may for example be achieved by arranging air flow directing flanges on the inside of the body portion 102.

In the conceptual illustration as shown in Fig. 1, the face mask 100 has been provided with a first 108 and a second filter member arranged at the first and the second air flow channel, respectively. The second filter member, as well as the second air flow channel is occluded in Fig. 1. However, the face mask 100 is preferably symmetric, meaning that the face mask 100 has an essentially similar appearance on a left and right-hand side of the user.

It may in some embodiments, however not shown in Fig. 1, be possible to equip each of the first 104 and the second air flow channel with a first and a second one-way valve. The first and the second one-way valve may in a first embodiment function in such a manner that air exhaled from the user is directed through the first and the second one-way valve, rather than passing through the filter members 108.

However, in a second embodiment it may be possible to allow the first and the second one-way valve to be configured such that the first air flow channel 104 is used when the user draws air, and the second air flow channel is used when the user exhales air. It may in such an embodiment be possible to arrange the respective one-way valves upstream or downstream of the respective filter member.

Accordingly, air may in this embodiment for example be drawn through the first one-way valve, pass through the first filter member 104 and then reach the user. The second one-way valve us here closed. When exhaling, the first one-way valve is closed, and the air will instead pass through the second filter member and then the second one-way valve before exiting at the external opening provided in relation to the second air flow channel.

The filter members 108 may in some embodiments be formed from a foam material, similar to the illustration presented in Fig. 1. However, in some embodiments it may be desirable to manufacture the body portion 102 of a paper material. It may as such also be desirable to manufacture the filter members from a paper material. Possibly, a paper-based filter member could in some embodiments comprise a crimped paper section.

It could within the scope of the present disclosure be possible to combine the body portion 102 and the filter members 108 from different materials. In one example the body portion 102 could be formed from an at least partly polymeric material, whereas the filter members 108 could be formed from a foam or a paper material.

It may, when the body portion 102 is formed from a paper material, be possible to provide the paper-based body portion 102 with an air impermeable member. For example, such an air impermeable member could include a coating on an inside or an outside of the body portion 102. The air impermeable member could for example be provided as a wax or polymeric coating.

In some embodiments of the present disclosure it may be possible to make use of replaceable filter members, possibly provided as cartridges that may be inserted into recesses provided at the body portion 102 at the first and the second air flow channel 104 and in relation to the external openings 106.

The first 108 and the second filter member may also, optionally comprise an absorbent element. The absorbent material could in some embodiments comprise a so-called super absorbent. By means of introducing an absorbent material it could be possible to even further reduce any unwanted exhaled airborne particles.

For improving the safety for the end user, it may be possible to equip the body portion to also comprise a face shield (not shown in Fig. 1), where the face shield is configured to cover the user’s eyes. Such a face shield may for example be provided as an integrated element of the body portion 102. Alternatively, the face shield may be made from a different material and be sealed as well as connected to the body portion 102. It may in some embodiments be possible to manufacture the face shield from a transparent plastic material.

In Fig. 2 there is presented an extension of the face mask 100 shown in Fig. 1, here further comprising a face shield 202 configured to cover the user’s eyes. The face shield 202 is preferably connected to the body portion 102 in such a way that is can be ensured that no air is leaking between the face shield 202 and the body portion 102 in a forward direction. The face shield 202 is in Fig. 2 shown to be connected to the outside surface of the body portion 102, however it is also possible and within the scope of the present disclosure to connect the face shield 202 to an inside or at an upper edge of the body portion 102.

In Fig. 3 A there is presented a face mask 300 according to an alternative embodiment of the present disclosure. The face mask 300 as shown in Fig. 3A is illustrated to show the backside of the face mask 300 that is intended to be positioned towards the face of the user. The face mask 300 is in Fig. 3A shown to be arranged in a folded manner, where the paper-based body portion 102 has been folded. The body portion 102 is in Fig. 3 A divided into a (shaded) center portion 302 and two end portions 304. The center portion 302 is here impermeable to air, whereas the end portions 304 are permeable to air and will function as filters when in operation. An increased number of folds (and “depth” of the folds) will ensure that the face mask 300 is following the face of the user. Also, by increasing the number of folds at the end portions 304, the filter area may be increase.

The face mask 300 is further provided with an upper 306 and a lower 308 sealing member that will seal the face mask 300 to the face of the user while at the same time ensuring that the face mask 300 is arranged at a defined distance from the face of the user. In a preferred embodiment the upper 306 and lower 308 sealing member is formed from a preferably (in comparison) soft material to allow wearing the face mask 300 to be comfortable. A thickness of the upper 306 and lower 308 sealing member is preferably around 10 mm, possibly between 5 - 20 mm. The upper 306 and lower 308 sealing member may in some embodiments be formed from a super absorbent material. The super absorbent material is preferably manufactured from a paper based product, thereby reducing an environmental impact of the face mask 300, making the face mask 300 easy to recycle.

By distancing the face mask 300 from the face of the user by means of the upper 306 and lower 308 sealing member the first and the second air flow channels, as discussed above, will be formed. Combining the first and the second air flow channels with the fact that the center portion 302 is impermeable to air and the fact that the end portions 304 are permeable, will ensure that the user will to both draw and subsequently exhale respiration air at an area in close vicinity of the ears of the user. To ensure that the air is drawn/exhaled in vicinity of the ears of the user the face mask 300 has an extended length as compared to a prior-art face mask. In one embodiment, the two end portions 304 corresponds to the extension in length of the face mask 300 as compared to a prior-art face mask. In a preferred embodiment it may be desirable to provide the inside surface of the body portion 102 with an absorbent member at least in front of the mouth and the nose of the user, preferably at the center portion 302 of the body portion 102. The absorbent member is provided for “collecting” a portion of particles in the air being expelled from the user. The absorbent member will as such “dry out” the expelled air, thereby reducing the amount of particles in the air that is to pass the filter members at the end portions 304 of the face mask 300. A reduction of liquids in the expelled air will increase the lifetime of the filter members, in turn reducing a resistance when air is to be draw through the filter members. That is, in prior-art implementations the liquids (particles) in the expelled air will “clog” the filter members over time, thereby making it harder and harder for the user to breath.

In some embodiments the absorbent member is manufactured from a paper based super absorbent material, similar to the upper 306 and lower 308 sealing member. The absorbent member may in some embodiments be provided as a coating to the center portion 302. However, the absorbent member may also be an integrated portion of the body portion 102.

In some embodiments it may also be desirable to provide at least a portion of an outside surface of the face mask 300 with a component or substance for reducing an amount of virus and/or bacteria. In some embodiments it may for example be possible to include e.g. a copper or silver-based component at the outside surface of the face mask 300. Other components/sub stances are however possible and within the scope of the present disclosure.

Turning now to Figs 4A and 4B, presenting a face mask 400 according to a still further alternative embodiment of the present disclosure. As is shown in Fig. 4A, the face mask 400 comprises a central body portion 402, where the central body portion 402 is non- penetrable and possibly can comprise a composite material. Preferably, an outside of at least the central body portion 402 of the mask 400 is, similar to the discussion above, coated with an anti-viral and/or anti-bacterial coating, allowing this area of the mask to be touched. Such an embodiment may greatly simplify fitting/removing/adjusting the mask. The anti-viral and/or anti-bacterial coating may for example be sprayed at the outside of the mask 400 during manufacturing of the mask 400.

The side portions 404 and 406, formed at the sides of the face of the user and extending towards the ears of the user are arranged to form the first and the second air flow channels, facing backwards in relation to the face of the user. The side portions 404 and 406 are in some embodiments of the present disclosure provided with a filter material, as has been discussed above and will be further elaborated below.

As is apparent from Fig. 4A, the cheeks of the user will form “one side” of the in combination with the air flow channels, and the material of the side portions 404, 406 will form the “other side” of the air flow channels. Air to and from the mouth and nose of the user will thus be allowed to “travel” in the airflow channels. In a preferred embodiment the side portions 404, 406 are formed from a material that has been selected to allow for a “crease” or fold that extends from a corresponding crease/fold in the central body part 402towards the ear of the user. The crease/fold will allow for an increase airflow to and from the mouth/nose of the user though the air flow channels.

In Fig. 4B there is provided a detailed illustration of the face mask 400, specifically focusing on the intrinsic parts and hos the mask 400 is arranged. In Fig. 4B, the inside of the central portion 402 of the mask 400 as well as the side portions 404 and 406 are illustrated.

The inside of the central portion 402 is in the illustrated embodiment lined with an absorbent material 408 that has been arranged to reduce moisture in the mask 400 and thus reduce the risk of skin problems. The absorbent material 408 will further improve comfort for the user during prolonged use of the mask 400. The absorbent material 408 may for example be a so called super absorbent polymer, where such a super absorbent polymer may be arranged to absorb moisture up to several hundred times its own weight. The absorbent material 408 will further ensure that the mask 400 may be allowed to have a tight fit without causing skin abrasions.

The central portion 402 further comprises a permeable layer 410 that is provided to ensure that the respiration air drawn and subsequently exhaled by the user cannot pass through the central portion 402. Additionally, and in line with the discussion above (at least) the central portion 402 is provided with an anti-viral and/or anti-bacterial coating 412. The coating 412 may be provided as a separate layer (as indicated in Fig. 4B), or as a coating (as discussed above) provided onto the permeable layer 410.

The side portions 404 and 406 are, as illustrated in Fig. 4B arranged as a layered structure comprising an inner layer 414 in the form of an absorbent material, being similar or the same as used for the central portion 402. An outside facing side of the side portions 404 and 406, outside as also seen from the inner layer 414, is then preferably provided with a filter layer 416 that has been arranged to maintain undesirable particles in the air being drawn and exhaled by the user, thus ensuring that the air to and from the user is as free as possible from unwanted particles.

The mask 400 further comprises an arrangement 418 for ensuring that the mask 400 fits snug to the nose of the user. Such an arrangement 418 may for example comprise some form of thin metal wiring 420 that has been embedded in a soft material 422. The user may then easily bend the arrangement 418 to ensure that the mask 400 aligns with the nose of the user.

Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. Also two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on designer choice. All such variations are within the scope of the disclosure. Additionally, even though the present disclosure has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art. Variations to the disclosed embodiments can be understood and effected by the skilled addressee in practicing the claimed present disclosure, from a study of the drawings, the disclosure, and the appended claims. Furthermore, in the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

Claims

1. A face mask, comprising:

- a body portion configured to be placed over a mouth and at least part of a nose of a user, the body portion being impermeable to air at an area corresponding to the mouth and the nose of the user, and

- a fastening member attached to the body portion or air flow channels and configured for retaining the body portion onto the face of the user, wherein:

- the body portion comprises a first and a second air flow channel arranged as an integrated part of the body part on a left and a right-hand side, respectively, of the user’s face, wherein each of the first and the second air flow channel is adapted to allow the user to both draw and subsequently exhale respiration air, and

- the first and the second air flow channel are each provide with an external opening that is arranged to face downwards or backwards relative to the mouth of the user, wherein the first and the second air flow channel are permeable to air at the external openings.

2. The face mask according to claim 1, wherein the external openings are positioned relatively below an ear of the user.

3. The face mask according to any one of claims 1 and 2, further comprising a sealing member adapted to seal the body portion to the face of the user.

4. The face mask according to any one of the preceding claims, wherein the body portion has an inside surface facing the user that is structured to maximize a direction of an air flow through the first and the second air flow channel.

5. The face mask according to any one of the preceding claims, further comprising a first and a second filter member arranged at the first and the second air flow channel, respectively.

6. The face mask according to claim 5, wherein the first and a second filter member is replaceable.

7. The face mask according to any one of claims 5 and 6, wherein the first and a second filter member comprises an absorbent element.

8. The face mask according to any one of claims 5 - 7, wherein the filter members are manufactured from the same material as the body portion.

9. The face mask according to any one of the preceding claims, wherein the paper material comprises an impermeable member.

10. The face mask according to claim 9, wherein the impermeable member comprises a coating arranged at an outer surface of the body portion.

11. The face mask according to any one of the preceding claims, wherein the body portion further comprises a face shield configured to cover the user’s eyes.

12. The face mask according to claim 5, further comprising a first and a second one-way valve arranged at the first and the second air flow channel, respectively.

13. The face mask according to any one of the preceding claims, wherein the body portion comprises a plurality of folded sections at least in front of the mouth and the nose of the user.

14. The face mask according to any one of the preceding claims, further comprising a sealing element attached to an inside of the face mask at a portion of an upward and downward facing side of the face mask.

15. The face mask according to claim 14, wherein the sealing element has a thickness of at least 5 mm, preferably 10 mm.

16. The face mask according to any one of the preceding claims, wherein the inside surface of the body portion is provided with an absorbent member at least in front of the mouth and the nose of the user.

17. The face mask according to any one of the preceding claims, wherein at least a portion of an outside surface of the face mask is provided with a component for reducing an amount of virus and/or bacteria.

18. The face mask according to any one of the preceding claims, wherein the body portion is formed from a polymer-based material.