A mask for inhibiting the transmission of droplets including:          a first wall including a first portion;     a second wall including a second portion;     wherein the first and second wall are connected to each other at or near their peripheries to define a space therebetween;     an opening which extends between the first and second portions and which, in use, overlies a user's mouth;     a first connection which connects the first portion to the second portion to inhibit communication between the opening and the space;     a transparent wall which covers the opening; and     a second connection which connects the transparent wall to the first or second walls.

FIELD

The present invention relates to the field of masks. In particular, the present invention relates to masks for use in covering a user's mouth and nose to inhibit the transmission of droplets.

BACKGROUND

Masks which cover a user's mouth and nose are well known. In particular, they have been found to be effective at reducing the transmission of droplets to and from a user's mouth and nose. This is of particular importance for the health of the population and in particular in hospital, clinical and surgical environments.

An issue with masks is that it is not possible to view a user's mouth when they are talking. People intuitively look at a person's mouth when they are talking to understand speech and also to understand emotions that a user may be experiencing. In particular, deaf people look at people's mouths to lip read and so know what a person is saying. Therefore, masks create a barrier to communication which is clearly undesirable.

Attempts have been made to create masks through which a person is able to view a user's mouth, e.g. through the use of transparent coverings applied over an opening in the mask. However, such masks do not satisfy the strict safety criteria required for the hospital, clinical and surgical environments and so are unsuitable for use in those settings. In particular, such prior art masks suffer from a compromised performance in terms of inhibiting transmission and/or the transparent coverings are prone to becoming obscured through fog or mist forming on them during use.

The present invention at least seeks to ameliorate the above issues.

BRIEF DESCRIPTION OF THE INVENTION

According to a first aspect of the invention we provide a mask for inhibiting the transmission of droplets including:a first wall including a first portion;a second wall including a second portion;wherein the first and second wall are connected to each other at or near their peripheries to define a space therebetween;an opening which extends between the first and second portions and which, in use, overlies a user's mouth;a first connection which connects the first portion to the second portion to inhibit communication between the opening and the space;a transparent wall which covers the opening; anda second connection which connects the transparent wall to the first or second walls.

The first connection and/or second connection each may form a closed path.

The first and second portions may define respective parts of the opening.

The first connection may effect joining or fusion of the first and second portions together.

The second connection may connect the transparent wall, optionally or preferably a periphery of the transparent wall, to the first or second wall near or around the first or second portion thereof.

The second wall may include a surface which faces towards a user's face during use.

The transparent wall may be positioned on the surface.

The first connection, in front view, may overlap, overlie or be contiguous and/or congruent with the second connection.

The opening and/or the transparent wall and/or the first connection and/or the second connection may form the same shape.

The opening and/or the transparent wall and/or the first connection and/or the second connection may be concentric with each other.

The opening may be oval shaped.

The transparent wall may be oval shaped.

The first connection may be oval shaped.

The second connection may be oval shaped.

The first connection may be provided by a weld.

The first connection may be provided by an ultrasonic weld.

The second connection may be provided by an adhesive.

The adhesive may be positioned between the second wall and transparent wall or the first wall and transparent wall.

The adhesive may be positioned between the first/second portion and the transparent wall.

The adhesive may include a backing layer.

The backing layer may be formed from polyethylene (PE).

The backing layer may include first and second sides.

First and second adhesive layers may be attached to the first and second sides respectively.

The first adhesive layer may be attached to the second wall.

The second adhesive layer may be attached to the transparent wall.

The adhesive may include a synthetic rubber adhesive.

The first and/or second adhesive layer may include a synthetic rubber adhesive.

The transparent wall may include, or be formed from, polyethylene terephthalate (PET).

The mask may include a third wall connected to the first and second walls about their respective peripheries and positioned in the space between the first and second walls.

The first wall may be a sheet material, e.g. a hydrophobic material or a hydrophobic spunbond polypropylene material.

The second wall may be a sheet material, e.g. a hydrophilic material or a hydrophilic spundbond polypropylene material.

The third wall may be a sheet material, e.g. a meltblown polypropylene material.

The mask may include a third wall including a third portion that the opening extends through and/or the first connection connects the first, second and third portions.

The mask may include a positioning member for assisting in positioning a mask on a user, preferably for positioning the mask on a nose of a user.

The positioning member may be positioned at a top edge of the first and/or second wall.

The mask may include first and second attachment formations for attaching the mask to a user's face.

The first attachment formation may be a strap, or loop of material, which is attached to the first and/or second wall, preferably a first side of the first and/or second wall, which, in use, may be positioned around a user's ear.

The second attachment formation may be a strap, or loop of material, which is attached to the first and/or second wall, preferably a second side of the first and/or second wall, which, in use, may be positioned around a user's ear.

The mask may be a two-ply or three-ply mask with the first/second and/or third walls forming respective layers of the mask.

According to a second aspect of the invention we provide a method of manufacturing a face mask, including the following steps:a) providing a mask including first and second walls including first and second portions respectively and an opening which extends between the first and second portions and a first connection which connects the first portion to the second portion;b) providing a transparent wall;c) positioning the transparent wall so as to cover the opening; andd) connecting the transparent wall to the first or second walls over the opening by a second connection.

According to a third aspect of the invention we provide a method of manufacturing a face mask, including the steps of:a) providing first and second walls including first and second portions respectively;b) cutting an opening through the first and second portions;c) optionally connecting the first and second portions together by a first connection;d) providing a transparent wall;e) positioning the transparent wall so as to cover the opening; andf) connecting the transparent wall to the first or second walls over the opening by a second connection.

The step of providing a transparent wall may include the step of providing a transparent wall sheet.

The step of providing a transparent wall may include the step of cutting the transparent wall from the transparent wall sheet.

The step of connecting the transparent wall to the first and/or second walls over the opening by a second connection may include the second connection being formed by applying an adhesive to connect the transparent wall to the first or second wall.

Applying the adhesive to connect the transparent wall to the first and/or second wall may include providing an adhesive sheet including the adhesive and a release sheet on which the adhesive is positioned.

Applying the adhesive to connect the transparent wall to the first and/or second wall may include cutting the adhesive to match the shape of the transparent wall.

Applying the adhesive to connect the transparent wall to the first and/or second wall may include removing an inner portion of the adhesive so that a peripheral portion of the adhesive remains on the release sheet.

Applying the adhesive to connect the transparent wall to the first and/or second wall may include applying the transparent wall to the peripheral portion of the adhesive positioned on the release sheet.

The step of connecting the first and second walls may include welding the first and second portions of the walls together around the opening, or the first connection may be a weld connection between the first and second portions of the walls around the opening.

The step of providing the first and second walls may further include the step of providing first and second wall sheets.

The step of providing the first and second walls may further include the step of cutting the first and second walls from the first and second wall sheets.

The method may further include the step of providing the first and second wall sheets including providing the first and second wall sheets as a roll and unrolling the first and second wall sheets prior to cutting the first and second walls from the first and second wall sheets.

The method may further include the step of providing the transparent wall sheet includes providing the transparent wall sheet as a roll and unrolling the transparent wall sheet prior to cutting the transparent wall from the transparent wall sheet.

The method may further include the step of providing an adhesive sheet as a roll and unrolling the adhesive sheet prior to cutting the adhesive to provide the second connection.

The opening may be generally oval shaped.

The transparent wall may be generally oval shaped.

The transparent wall may be formed from polyethylene terephthalate (PET).

The adhesive may be positioned between the second and transparent walls.

The adhesive may be positioned between the second portion and the transparent wall.

The adhesive may include a backing layer.

The backing layer may be formed from polyethylene (PE).

The backing layer may include first and second sides.

First and second adhesive layers may be attached to the first and second sides respectively.

The first adhesive layer may be attached to the second wall.

The second adhesive layer may be attached to the transparent wall.

The adhesive may include a synthetic rubber adhesive.

The third aspect of the invention may include one or more or all of the features of the first and/or second aspects of the invention.

The second aspect of the invention may include one or more or all of the features of the first and/or third aspects of the invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring toFIGS.1to11there is disclosed a mask10for inhibiting the transmission of droplets.

The mask includes first, second and third walls12,14,16(as can be seen inFIGS.4,6and7), commonly known as a 3-ply mask. In other embodiments more or fewer walls may be provided without departing from the scope of the present invention. For example, the mask may include first and second walls only, or may include four or more walls without departing from the scope of the present invention.

The first and second walls12,14in use are positioned over a user's mouth and nose (as shown inFIGS.10and11). In use, the first wall12faces away from a user so as to form an outer wall and the second wall14faces towards the user so as to form an inner wall. In particular, the first wall12includes a surface1200which faces away from a user. The second wall includes a surface1400which faces towards a user's face during use.

The first and second walls12,14may each permit air to pass therethrough whilst inhibiting droplets, e.g. the first and/or second walls12,14are gas permeable. The first and second walls12,14may be made from a filter material or a material that functions as a filter.

The first wall12is a sheet material formed from a hydrophobic spunbond polypropylene material (SBPP). The first wall12is blue to indicate that it is this wall which should face outwardly in use. The second wall is a sheet material formed of a hydrophilic spunbond polypropylene material (SBPP), or spunbond polypropylene, in particular having a weight of 25 gsm. The second wall14is white to indicate that it is this wall which should face towards a user in use. The first and second walls12,14could be formed from other materials without departing from the scope of the present invention. For example, the first and second walls12,14could be formed from polyesters or other polyamides without departing from the scope of the present invention. The first wall12may have a hydrophobic coating applied to it, or be formed of a hydrophobic material, to inhibit the build-up of moisture on the first wall12. Alternatively the first wall12may include other hydrophobic materials. The second wall14may have a hydrophilic coating applied to it, or be formed of a hydrophilic material, to draw moisture from the first wall12and/or the third wall towards the second wall14. This may be advantageous in improving the efficiency of the mask.

The first and second walls12,14are connected to each other at or near their peripheries and define a space30therebetween (seeFIGS.6and7). In particular, the first, second and third walls12,14,16are connected about their respective peripheries, and optionally are coterminous. The third wall16is positioned at least partially within the space30between the first and second walls12,14. The walls12,14,16are connected about their respective peripheries but the rest of the walls, i.e. their respective inner regions, are not fixed together. This may not be the case in other arrangements.

Referring toFIG.5, the first and second walls have a respective top11and bottom13. The top and bottom11,13of the first and second walls12,14are folded in a direction from the second wall14to the first wall12and welded to form first and second seams which define a top edge60and a bottom edge62of the mask10. Referring toFIG.1, the first and second walls12,14have first and second respective sides15,17. The first and second respective sides15,17are welded to seal the first and second sides15,17to connect the first and second walls12,14at or near their peripheries. Where a third wall16is provided, it is similarly folded at its respective top and bottom to define the top and bottom edges60,62together with the first and second walls12,14. Respective sides of the third wall16may also be welded about their peripheries together with the sides15,17of the first and second walls12,14

The first and second walls12,14are generally rectangular in plan view. In embodiments the first and second walls12,14may be other shapes without departing from the scope of the present invention. For example, the first and/or second walls12,14, and/or third wall16may be square, oval, trapezoidal or kite shaped, or any other polygonal shape. In embodiments the first and second walls12,14and third wall16may have different shapes in plan view.

The third wall16is positioned, or sandwiched, between the first and second walls12,14(as shown inFIGS.6and7) and acts as a filter, e.g. it is gas permeable. In embodiments instead of, or in addition to, the third wall16the mask10may be provided with a filter positioned over an aperture in the first and/or second wall12,14. In the present embodiment the third wall16is generally rectangular in plan view. In particular, in the present embodiment the third wall16is the substantially the same size and shape as the first and/or second walls12,14. In other embodiments this may not be the case. In the present embodiment the third wall16is a sheet material. In particular, the third wall16is formed from a meltblown material, e.g. a meltblown polypropylene material. The material has a weight of 25 gsm. In other embodiments the third wall16may be formed from other filter materials as are well known in the art. For example, the third wall16may be formed of other non-woven forms of polypropylene, such as spunbond or spunlace polypropylene, and/or may include carbon without departing from the scope of the present invention.

The first, second and third walls12,14,16are each formed of respective materials having a weight of 25 gsm. In embodiments the first and/or second and/or third walls12,14,16may be formed of materials having a weight of at least 5 gsm, 10 gsm, 15 gsm or 20 gsm. In embodiments the first and/or second and/or third walls12,14,16may be formed of materials having a weight of at most 30 gsm, 35 gsm, 40 gsm or 45 gsm.

In the present embodiment the first and/or second and/or third walls12,14,16may each include a portion which extends over the opening28(seeFIGS.10and11). In embodiments this may be provided by the first and/or second and/or third walls12,14,16being pleated, as described below, or otherwise folded or positioned in front of the opening28. During use the portion of the first and/or second and/or third walls12,14,16which extends over the opening28may move such that they no longer overlie the opening28as the mask is stretched over a user's face (for example seeFIGS.8to11).

The first, second and third walls12,14,16are folded about first and second generally horizontal axes A1, A2(in plan view with the mask orientated horizontally) to form first and second pleats52,54in the mask10(seeFIGS.1and4). In embodiments one or both of the axes A1, A2may not be generally horizontal and may be, for example, inclined at an angle with respect to the upper edge60and/or the bottom edge62of the mask10. The pleats52,54are advantageous in enabling a secure fitment of the mask10to the user and ensuring the user is able to speak whilst wearing the mask.

Referring toFIG.2, when assembled the first, second and third walls12,14,16have a height Hw and width Ww. In the present embodiment the height Hw is 95 mm and the width Ww is 175 mm. In embodiments the first, second and third walls12,14,16may have a height Hw of at least 60 mm; 70 mm; 80 mm; or 90 mm. In embodiments the first, second and third walls12,14,16may have a height Hw of at most 100 mm; 110 mm; 120 mm; or 130 mm. In embodiments the first, second and third walls12,14,16may have a width Ww of at least 60 mm; 150 mm; 160 mm; or 170 mm. In embodiments the first, second and third walls12,14,16may have a width Ww of at most 180 mm; 190 mm; 200 mm; or 210 mm.

The axis A1about which the first pleat52is folded is positioned approximately 32 mm from the top edge60in a direction generally orthogonal to the axis A1. In embodiments the first pleat52may be positioned at least 5 mm, 15 mm, 25 mm or 30 mm from the top edge60in a direction generally orthogonal to the axis A1. In embodiments the first pleat52may be positioned at most 35 mm, 40 mm, 45 mm or 50 mm from the top edge60in a direction generally orthogonal to the axis A1.

The axis A2about which the second pleat54is folded is positioned approximately 24 mm from the bottom edge62in a direction generally orthogonal to the axis A2. In embodiments the second pleat54may be positioned at least 5 mm, 10 mm, 15 mm or 20 mm from the bottom edge62in a direction generally orthogonal to the axis A2. In embodiments the second pleat54may be positioned at most 25 mm, 30 mm, 35 mm or 40 mm from the bottom edge62in a direction generally orthogonal to the axis A2.

In the present embodiment the first and second pleats52,54differ in the degree to which they are folded over and the direction of the folds. For example, the first pleat52is folded so that it lies in front or to the front side of a transparent wall34(seeFIG.5), described in more detail below, whereas the second pleat54is folded so that it lies behind the transparent wall34or to the rear side of transparent wall34. In embodiments the first and second pleats52,54may lie to the same side of the transparent wall34. Each of the first and second pleats52,54are formed by two folds that form an S-shape

Referring toFIGS.4,6and7the first, second and third walls12,14,16include respective first, second and third portions22,24,26. An opening28extends between the first, second and third portions22,24,26. The first portion22and the second portion24, or the first portion22, second portion24and the third portion26, define respective parts of the opening28. The portions22,24and/or26are regions of the walls12,14,16which are proximate to the opening28, or extend near or around the opening. The opening28is generally oval shaped. The first, second and third portions22,24,26are positioned generally centrally in the first, second and third walls12,14,16in the present embodiment. In embodiments the first, second and third portions22,24,26may be positioned closer to the top or bottom edge60,62of the first, second and third walls12,14,16and/or the first or second sides15,17without departing from the scope of the present invention. In the present embodiment the first, second and third portions22,24,26are a similar shape to the opening28, and in particular are generally oval shaped. In embodiments the first, second and third portions22,24,26may be other shapes such as square, rectangular, circular, stadium shaped or any other polygonal shape without departing from the scope of the present invention. In embodiments the opening28may extend between the first and second portions22,24. In embodiments the opening28may be square, rectangular, circular, stadium shaped or any other polygonal shape without departing from the scope of the present invention.

Referring toFIG.3, in the present embodiment the opening28is positioned generally centrally in the first and second walls12,14. In particular, the opening28has a top280and a bottom282and first and second sides284,286(seeFIGS.2and3). The top280is positioned a distance O3from the top edge60of 32 mm. The bottom282is positioned a distance O4from the bottom edge62of 24 mm. The first side284is positioned a distance O5from the first side15of 32.5 mm. The second side286is positioned a distance O6from the second side17of 32.5 mm. In embodiments the top280, bottom282, first side284and second side286may be positioned at least 5 mm, 10 mm, 15 mm, or 20 mm from a respective edge or side of the first and/or second walls12,14. In embodiments the top280, bottom282, first side284and second side286may be positioned at most 25 mm, 30 mm, 35 mm, or 40 mm from a respective edge or side of the first and/or second walls12,14.

The mask10includes a positioning member70(seeFIG.5) for assisting in positioning a mask on a user and in particular for positioning the mask on a nose of a user. The positioning member, or nose band,70is positioned at the top edge60of the mask in a generally central position of the mask10and extends lengthwise of the mask10. In particular the nose band70is positioned adjacent the top11of the first and second walls12,14in the fold of the first and second walls12,14which forms the top edge60of the mask10. In other words the nose band70is enveloped by an outwardly facing surface of the first wall12. The nose band70is then welded into position as part of the welding process which defines the top and bottom edges60,62. In embodiments the nose band70may be positioned on an outwardly facing surface of the first and/or second wall12,14or may be positioned in between the first and/or second and/or third walls12,14,16without departing from the scope of the present invention.

A centre of the nose band70lies above the centre of the opening28.

The nose band70in the present embodiment is resiliently deformable and may be moulded to a user's face. In embodiments the nose band70may be relatively rigid. In embodiments the nose band70may be relatively soft to provide added comfort to a user and to improve sealing of the mask10to a user's face (as demonstrated inFIGS.10and11where the nose band70is following the contour of the nose on the face). In the present embodiment the nose band70is a metal wire, or first and second substantially parallel metal wires, which a user may deform when applying the mask to their face. The wire may be a single core wire or may be a double core wire. The wire may be formed of aluminium or any other suitable metal as is known in the art. In embodiments the wire may be formed from mouldable plastics.

The wire in the present embodiment has a generally circular cross-section. In other embodiments the wire may have a generally flat cross-section, a triangular cross-section or other polygonal cross-section without departing from the scope of the present invention. The nose band70has a length of 110 mm and a diameter of 3.0 mm. In embodiments the nose band70may have a length of at least 90 mm, 95 mm, 100 mm, or 105 mm. In embodiments the nose band70may have a length of at most 115 mm, 120 mm, 125 mm, or 130 mm.

The mask10includes first and second attachment formations72,74for attaching the mask10to a user's face (seeFIGS.3,10and11in particular). In the present embodiment the first and second attachment formations72,74are provided as straps which are attached to the first and second sides15,17of the first and second walls12,14and which, in use, are positioned around a user's ears. In particular the first and second attachment formations72,74have respective first and second ends720,722,740,742. In the present embodiment the respective first ends720,740are positioned towards the top edge60of the mask10and the second ends722,742are positioned towards the bottom edge62of the mask10.

In embodiments only a single attachment formation may be provided. For example, a single attachment formation may be provided which is attached to the first and second sides15,17of the first and second walls12,14and which in use passes around the back of a user's head. Two or more such attachment formations could be provided at or near the top and bottom edges60,62of the mask10to improve fitment of the mask10to a user.

The straps72,74are formed from an elastic material to permit secure fitment of the mask10to a user. In particular, the straps72,74include nylon and spandex. The straps72,74in particular include latex free elastic or elastic not made with natural rubber latex. In embodiments other materials could be used to form the straps72,74without departing from the scope of the present invention. For example, the straps72,74could be formed from the same material as the first and/or second and/or third walls12,14,16. Such straps72,74could be formed as extensions of the first and/or second and/or third walls12,14,16. The straps72,74in cross-section are relatively flat to enhance user comfort. In embodiments the straps72,74may have a generally circular cross-section, a triangular cross-section or other polygonal cross-section without departing from the scope of the present invention.

The straps72,74are welded onto the first or second wall12,14in the present embodiment. In embodiments the straps72,74may be connected to the mask10by adhesive or may be stitched in or may be connected by any other means as is well known in the art. In embodiments the straps72,74may be connected to the first wall12and/or the second wall14and/or the third wall16without departing from the scope of the present invention.

The straps72,74each have a length of 180 mm. In embodiments the straps72,74may have a length of at least 140 mm, 150 mm, 160 mm, or 170 mm. In embodiments the straps72,74may have a length of at most 190 mm, 200 mm, 210 mm, or 220 mm.

In the present embodiment the first and second attachment formations72,74are substantially the same. In embodiments the first and second attachment formations72,74may differ.

Referring toFIGS.4,7to11, a first connection32connects the first portion22to the second portion24, or the first portion22, second portion24and third portion26, to inhibit communication between the opening28and the space30. The first connection32effects joining or fusion of the first and second portions22,24together. In the present embodiment the first connection32forms a closed path around the opening28. In particular the first connection32is oval shaped.

In the present embodiment the first connection32is provided by an ultrasonic weld, preferably at 20 kHz, between the first and second portions22,24. In other embodiments other connection means could be used without departing from the scope of the present invention. Other types of weld could be used, for example heat welding, radiofrequency, or electron beam welding without departing from the scope of the present invention. Further, the first connection could be provided by other connection means such as an adhesive connection or bonding using a tie-layer could be used without departing from the scope of the present invention.

The mask10includes a transparent wall34, as shown inFIGS.1to11, and as mentioned above. The transparent wall34covers the opening28. In particular, the transparent wall34is attached over the opening28as described in more detail below. In particular a periphery of the transparent wall34overlies the second portion24of the second wall14. The transparent wall34in the present embodiment overlies the second portion24of the second wall14by 5 mm. In embodiments the transparent wall34may overlie the second portion24of the second wall14by at least 2 mm, 3 mm or 4 mm. In embodiments the transparent wall34may overlie the second portion24of the second wall14by at most 6 mm, 7 mm or 8 mm. By transparent, we mean that the wall34permits an observer to clearly see a user's mouth such that an observer can tell what movements the user's mouth is making. This is advantageous for permitting an observer who can lip read be able to understand what a user is saying to them. In the present example the transparent wall34is see-through, i.e. no colour or pigments are present in the wall34. However, in other embodiments the wall34may include a colour or pigment.

In the present embodiment the transparent wall34is a similar shape to the opening28, and in particular is oval shaped. In embodiments the transparent wall34may be square, rectangular, circular, stadium shaped or any other polygonal shape without departing from the scope of the present invention.

The transparent wall34has a thickness of 0.1 mm. In embodiments the transparent wall34may have a thickness of at least 0.05 mm; 0.06 mm; 0.07 mm; 0.08 mm; or 0.09 mm. In embodiments the transparent wall34may have a length of at most 0.11 mm; 0.12 mm; 0.13 mm; 0.14 mm or 0.15 mm.

The transparent wall34in the present embodiment is substantially gas and liquid impermeable. In particular, the transparent wall34includes, or is formed from, polyethylene terephthalate (PET). The transparent wall34includes first and second respective surfaces340,342on which a hydrophilic coating is applied. This is advantageous in reducing fogging of the transparent wall34in use. In embodiments the transparent wall34may include, or be formed from, polyester laminates, multilayer films including ethylene vinyl acetate (EVA), polyvinylidene chloride (PVDC), polyester, polyamides, or polyurethanes. Examples of suitable materials for the transparent wall34are 3M 9960 and 3M 9962. In embodiments, the transparent wall34may be made from a hydrophilic material and/or have a hydrophilic coating applied thereto. The transparent wall34may also be made from or be coated to be a microfluidic material.

As mentioned above, a second connection36connects the transparent wall34, optionally or preferably a periphery of the transparent wall34, to the second wall14, preferably near or around the second portion24thereof. The second connection36connects the outwardly facing surface342, i.e. facing away from the user, of the transparent wall34to the inwardly facing surface1400, i.e. facing towards the user, of the second wall14. The transparent wall34is closest to the user's face in comparison to the first, second and third walls12,14,16. In other words the transparent wall34is positioned on the surface1400of the second wall14. In particular, the second connection36is between the second portion24and the transparent wall34. In embodiments the second connection36may connect the transparent wall34, optionally or preferably a periphery of the transparent wall34, to the first wall12, preferably near or around the first portion22thereof.

The second connection36forms a closed path around the opening28. In particular, the second connection36is positioned at, and follows, a periphery38of the transparent wall34. This enables a secure connection of the transparent wall34to the second wall14whilst permitting a clear view of a user's mouth in use. In the present embodiment the second connection36is oval-shaped. The second connection36forms a barrier between the region that the transparent wall34overlies the second wall14(or overlies first wall12for embodiments where the transparent wall34connects thereto) so as to effectively seal this region with respect to the opening28.

In the present embodiment the second connection36is formed by an adhesive. Referring toFIG.6, in the present embodiment the adhesive is a double sided adhesive tape and, in particular, includes a backing layer46, preferably formed of polyethylene (PE), having first and second respective sides. In embodiments the backing layer46may alternatively be formed of polyester. First and second adhesive layers48,50are attached to the first and second respective sides. The first adhesive layer48is attached to the second portion24of the second wall14and the second adhesive layer50is attached to the periphery38of the transparent wall34. The first and/or the second adhesive layer48,50in the present embodiment are a synthetic rubber adhesive. In other embodiments other adhesives may be used without departing from the present invention. For example, a hot melt adhesive or a cured adhesive may be used without departing from the present invention. In embodiments the first and/or second adhesive layer48,50may be, or include, synthetic rubber, acrylate, EVA, PVA, PVC or epoxies. In embodiments the adhesive may include only an adhesive layer48. Non-limiting examples of suitable adhesives, or adhesive tapes, for the present invention are as follows: 3M 1510; 3M 1567; 3M 1504XL; 3M 9969.

The first connection32may be provided so that it does not extend all the way to the opening28. In other words, there are regions of the first, second and/or third portions22,24,26that are not connected together and extend past the first connection32to the opening28. As best seen inFIG.5, in embodiments, the second connection36may be provided so that it extends to, or close to, the edge of the opening28, in other words the second connection36may be contiguous and/or congruent with the opening28.

With reference toFIG.10, the first and second connections32,36may overlap each other. In particular, in the present embodiment, in plan view, the first connection32has inner and outer peripheries40,42and the second connection36has inner and outer peripheries43,45. The outer periphery42of the first connection32is positioned closer to the opening28than the outer periphery45of the second connection36and the inner periphery40of the first connection32is positioned further from the opening28than the inner periphery43of the second connection36. In embodiments this may not be the case. For example, the outer periphery40of the first connection32may be positioned further from the opening28than the outer periphery45of the second connection36. The inner periphery40of the first connection32may be positioned closer to the opening28than the inner periphery43of the second connection36. Alternatively, in embodiments, the first and second connections32,36in plan view may substantially overlie or be contiguous and/or congruent with each other.

In the present embodiment the first and second connections32,36are substantially the same shape. However, in other envisaged embodiments the first and second connections32,36may have different shapes. In embodiments the first and/or second connections32,36may be square, rectangular, circular, stadium shaped or any other polygonal shape without departing from the scope of the present invention.

In the present embodiment the opening28and the transparent wall34and the first connection32and the second connection36form the same shape. In embodiments the opening28and/or the transparent wall34and/or the first connection32and/or the second connection36form the same shape. Preferably the opening28and/or the transparent wall34and/or the first connection32and/or the second connection36are concentric with each other and optionally or preferably are oval shaped.

Referring toFIGS.12to26there is also provided a method of manufacturing a mask according to the present invention. A brief outline of the steps to manufacture the mask is provided in Table 1 below. The manufacturing process described below can be used to form a plurality of masks. However, for the sake of simplicity the process is described below in relation to a single mask. It will be readily appreciated that where a single feature of a mask has been described, e.g. an opening being formed, this process can be repeated multiple times to form multiple masks as will be understood by someone skilled in the art.

TABLE 1steps to manufacture a maskStepProcess stepSub Assembly1aCut 3 ply material or first, second and third wall sheets to roll width1bCombine first, second and third wall sheets into a 3 ply material1cFeed 3 ply material1dFeed in positioning member1eCut positioning member to size and position on the first and secondwalls sheets1fFold top and bottom of the first and second walls and weld intoposition1gCut the opening into the first, second and third portions1hConnect the first, second and third portionsFirst sub-assemblycomplete2aCut transparent wall material to roll width2bFeed in transparent wall sheet2cRemove excess adhesive from release sheet2dCut transparent wall from transparent wall material2eApply transparent wall to adhesiveSecond sub-assembly complete3aFeed transparent wall assembly3bFeed mask body roll3cApply transparent wall assembly to the mask body roll over theopening3dPress transparent wall onto the second portion3eFold first and second wall sheets to form pleats3fCut the first and second walls from the first and second wall sheets3gConnect first and second walls at the first and second sides3hFeed in attachment formations to first and second sides3iConnect attachment formations to the first and/or second wallsMask complete

At step1a(seeFIG.12) a 3 ply sheet130′ is cut to a correct width W1ready to be used to form the mask. In embodiments the 3 ply sheet may be supplied at the correct width to be used, and therefore need not be cut to width. In embodiments first, second and third wall sheets12′,14′,16′ may be provided which are formed of material from which the first, second and third walls12,14,16are to be constructed. Each of the first, second and third wall sheet12′,14′,16′ may be cut to a correct width W1ready to be used to form the mask.

Referring to step1bandFIG.13the first, second and third wall sheets12′,14′,16′ are provided which are formed of material from which the first, second and third walls12,14,16are to be constructed. Accordingly, the first and second walls are provided. The first and second walls are substantially as described above in relation to the mask10and include first and second portions22,24respectively. The first, second and third wall sheets are layered so that the third wall sheet is positioned between the first and second wall sheets and the second wall sheet is positioned at the bottom. In other words, the first, second and third wall sheets are combined to form a 3 ply sheet130′. In embodiments the first, second and third walls sheets12′,14′,16′ are provided as separate rolls which are unrolled and layered into a 3 ply sheet130′. Once layered the first, second and third wall sheets are rolled up ready to be used subsequently. In embodiments the first, second and third wall sheets may be supplied as a 3 ply sheet. In embodiments the first, second and third wall sheets may not be rolled up into a roll.

Referring toFIG.14and steps1cand1dthe 3 ply sheet130′ is unrolled and fed into the manufacturing line. A reel of positioning member material70′ is also fed into the manufacturing line.

Referring toFIGS.15(a) and (b)and step1ethe positioning member70is cut from the reel of positioning member material70′ and is positioned on the 3 ply sheet130′ ready to be fixed in position. In other words the positioning member70is positioned on the first and/or second wall sheets12′,14′. In embodiments the positioning member70may be supplied ready formed to the 3 ply sheet130′, or first and second wall sheets12′,14′.

As explained in relation to the mask10the first, second and third walls12,14,16have a top11and a bottom13, and the mask10has a top edge60and a bottom edge62. Accordingly, the 3 ply sheet also has a top11′ and a bottom13′. Referring toFIGS.16(a) and (b), at step if the top11′ and bottom13′ of the 3 ply sheet are folded on top of the first wall layer and are connected thereto to form the top edge and bottom edge60,62. In other embodiments the top11′ and/or bottom13′ of the 3 ply sheet130′ may be folded on top of the second wall layer and connected thereto. In particular the top11′ and bottom13′ are welded to the first wall layer. In embodiments the top11′ and bottom13′ may be connected using other means. For example the top11′ and bottom13′ may be adhered to the first and/or second wall layers, or may be stitched to the first and/or second wall layers without departing from the scope of the present invention.

As the top11′ is folded into position the positioning member70is fixed in position on the 3 ply sheet130′. In particular the positioning member70is positioned underneath the top11′ once it is folded over onto the first wall layer so as to be positioned at the top edge60. In other embodiments the positioning member70may be positioned below the top11′ once folded into position without departing from the scope of the present invention. Alternatively the positioning member70may be positioned on an outwardly facing surface of the top11′ once it is folded into position.

At step1g(seeFIGS.17(a) and15(b)) an opening28is cut through the first, second and third wall sheets12′,14′,16′. In particular, an opening28is cut through the first, second and third portions22,24,26using a hole punch150′. This is to permit viewing of a user's mouth through the transparent wall34once it has been connected or attached to the first and/or second wall sheets12′,14′. In the present embodiment the opening28is oval shaped. In embodiments the opening28may include one or more or all of the features described above in relation to the opening28.

At step1h(seeFIGS.18(a) and16(b)), the first, second and third portions22,24,26of the first, second and third wall layers are connected to create the first connection32. In the present embodiment the first, second, and third portions22,24,26are welded together using a heat sealer140′. In other words, the first connection32is a weld connection between the first, second, third portions22,24,26which would extend around the opening28when it is formed later in the process. The weld forms a closed path and may be substantially annular or oval shaped. In particular the connection between the first, second, and third portions22,24,26may include one or more or all of the features described above in relation to the first connection32of mask10. In embodiments where a third wall16is not provided, it will be understood that the opening28is cut into the first and second walls12,14and similarly the first and second portions22,24are connected together to form the first connection32.

After step1ha first sub-assembly sheet90′ for manufacturing a mask is formed. The first sub-assembly sheet90′ may then be rolled up ready for a subsequent manufacturing step.

At step2a(seeFIG.19) a transparent wall34is provided as part of a transparent wall sheet34′. The transparent wall sheet34′ may be provided as a roll. The transparent wall sheet34′ is then cut to the appropriate width W2for steps2bto2e. In embodiments the transparent wall sheet34′ may be provided at the appropriate width without departing from the scope of the present invention.

At steps2band2c(FIGS.20(a) to (c)) the transparent wall sheet34′ is unrolled and fed into the manufacturing process. Simultaneously an adhesive sheet36′ provided on a release sheet37′ is fed into the manufacturing process. The adhesive sheet36′ and/or the release sheet37′ may be provided as a roll. A pair of rollers160′ bring the transparent wall sheet34′ and the adhesive sheet36′ adjacent each other. A first adhesive shape is cut into the adhesive sheet36′ by a profile roller162′ which is supported by a further roller164′. The first adhesive shape is substantially the same shape as a periphery of the transparent wall34as provided on mask10. In other words the adhesive is cut to form a shape that matches the transparent wall34. In the present embodiment the first adhesive shape is oval shaped in plan view. An inner portion of adhesive sheet36′ is removed so a peripheral portion92′ of the adhesive remains on the release sheet37′ which will attach to a periphery of the transparent wall34on the transparent wall sheet34′. The peripheral portion92′ corresponds to the second connection36shown inFIG.4. In the present embodiment this is achieved by kiss-cutting the adhesive sheet36′ and the release sheet37′ so as to cut through the adhesive sheet36′ but leave the release sheet37′ intact. This is advantageous as is enables the adhesive to be stored again once prepared. Other methods of cutting the adhesive could be used without departing from the scope of the present invention.

At step2dthe transparent wall34is cut from the transparent wall sheet34′. In the present embodiment this is achieved by die cutting the transparent wall34from the transparent wall sheet34′. In embodiments the transparent wall34may be provided ready made thus removing the need to cut the transparent wall34from a transparent wall sheet34′.

At step2ethe transparent wall34is positioned over and aligned with the peripheral portion92′. The transparent wall34is then applied to the peripheral portion92′ whilst the peripheral portion92′ is on the release sheet37′. A second sub-assembly sheet100′ including the release sheet37′, peripheral portion92′ and transparent wall34is then rolled up. In embodiments the combination of the release sheet37′, peripheral portion92′ and transparent wall34may not be rolled up. In embodiments, the transparent wall sheet34′ may be presented to the peripheral portion92′ and die cut in the same step so that the transparent wall34is cut and applied to the peripheral portion92′ simultaneously.

Therefore, at the end of step2ea second sub-assembly sheet100′ has been manufactured. In embodiments alternative connection or attachment means to adhesives may be used. For example, welding could be used rather than, or in addition to, adhesive connections without departing from the scope of the present invention.

At steps3ato3c(seeFIG.21) the first and second sub-assemblies90′,100′ are unrolled and fed into the manufacturing process. The transparent wall34and peripheral portion92′ of adhesive are positioned over the opening28in the first sub-assembly90′. An application roller110′ is then used to apply the transparent wall34and peripheral portion92′ of adhesive around the opening28to cover the opening28. Therefore, this step includes the second connection being formed by applying the adhesive36to connect the transparent wall34to the first or second wall12,14. A further roller112′ is used to assist the application roller110′. The release sheet37′ and excess adhesive are then removed by a waste roller120′.

At step3d(seeFIG.22) the transparent wall34and adhesive36(as peripheral portion92′) are pressed onto the second portion24of the second wall sheet14′ by a press114′. In other words, this process connects the transparent wall34to the first or second walls12,14whilst they are part of the first and second wall sheets12′,14′. This process also forms a second connection36. The second connection36is substantially as described above in relation to the mask10.

At step3e(seeFIG.23) the first and second wall sheets12′,14′ are folded to form the first and second pleats52,54. In embodiments more or fewer pleats may be formed in the mask. In embodiments no pleats may be formed in the mask10.

At steps3fand3g(seeFIG.24) the first, second and third walls12,14,16are cut from the first, second and third walls sheets12′,14′,16′ along the lines C1, C2. The lines C1, C2are generally orthogonal to the top and bottom edges60,62. In embodiments where the first, second and third walls12,14,16are provided preformed step3fmay be omitted.

In the present embodiment the first, second and third walls12,14,16are cut from the first, second and third wall sheets12′,14′,16′ after the adhesive36and transparent wall34are applied to the first, second and third wall sheets12′,14′,16′. In embodiments the first, second and third walls12,14,16are cut from the first, second and third wall sheets12′,14′,16′ before the adhesive36and transparent wall34are applied to the first, second and third wall sheets12′,14′,16′.

At step3g(seeFIG.25) the sides15,17of the first, second and third walls12,14,16are connected to each other such that the first, second and third walls are connected at or near their peripheries. In the present embodiment the sides15,17are connected by welding the first, second and third walls12,14,16together. In embodiments the sides15,17may be connected by adhesive, stitching or any other appropriate means known in the art.

At steps3hand3i(seeFIG.26) the first and second attachment formations72,74are fed into the manufacturing process. In the present embodiment the attachment formations72,74have already been cut to size to feed into the manufacturing process. In embodiments one or more attachment formation reels may be provided from which the attachment formations72,74are cut to then be fed into the manufacturing process.

The method includes the step of positioning the attachment formations72,74on the mask10. The attachment formations72,74are attached as described in relation to the mask10above. In particular, in the present embodiment the first and second respective ends of the first and second attachment formations720,722,740,742are positioned to respective sides15,17of the mask10at the upper edge60and bottom edge62.

At step3ithe attachment formations72,74are connected to the first and/or second walls12,14.

In particular, the first and second respective ends of the first and second attachment formations720,722,740,742are connected to the first and/or second walls12,14. In the present embodiment the attachment formations72,74are welded to the first and/or second walls12,14. In particular the first and second respective ends of the first and second attachment formations720,722,740,742are welded to the first and/or second walls12,14, preferably by an ultrasonic weld. In embodiments the first and second attachment formations72,74may be connected to the first and/or second walls12,14by adhesive, stitching or any other appropriate means known in the art.

At this point the mask10is completed and is then packaged ready for shipping.

In the present embodiment the method of manufacture includes making the first and second sub-assemblies90′,100′. In embodiments the first and second sub-assemblies90′,100′ may be provided preformed. In such embodiments only steps3ato3iare necessary as steps1ato2ewill have been completed in another manufacturing process.

Masks made according to embodiments of the present invention have been found to be particularly effective at preventing transmission of droplets whilst maintaining the visibility through the transparent wall of the mask. This is highly advantageous in comparison to the prior art masks currently available that fail in one or both of these aspects. Advantageous effects are achieved through the present invention utilising two separate connections, namely first connection32and the second connection36that respectively connect the first, second and third walls12,14,16together, and the first or second wall12,14to the transparent wall34. In particular, the use of first and second connections32,36has been found to be advantageous in preventing the transparent wall34from peeling away from the mask10.

The below table sets out how the mask10and various components thereof have been found to pass a number of medical and regulatory test standards. This evidences the high performance of the mask10for use in medical settings, e.g. surgical settings, in particular. The mask according to the present invention offers a design and performance that performs in a comparable manner to a Type IIR mask for source control and provides an equivalent level of wearer protection against droplets and splashes to a Type IIR medical mask, as specified in BS EN14683:2019for medical masks as stipulated in the UK Government's Guidance for Transparent face masks technical specification guidance document sections 5.6 and 6.2 (filtration efficiency and probable mechanism of action) making it safe to the wearer at a comparable level.

The invention may also broadly consist in the parts, elements, steps, examples and/or features referred to or indicated in the specification individually or collectively in any and all combinations of two or more said parts, elements, steps, examples and/or features. In particular, one or more features in any of the embodiments described herein may be combined with one or more features from any other embodiment(s) described herein.

Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and/or to encompass equivalents.