FACE MASK

A face mask is provided. The mask comprises a body defining an interior side and an exterior side of the face mask; a one-way inlet valve that only allows gas to pass from the exterior side of the body to the interior side; and a one-way outlet valve that only allows gas to pass from the interior side of the body to the exterior side. By providing a face mask configured in this manner, the mask is able to provide fresh air to the wearer while reducing the likelihood of contamination by pathogens or other toxic matter.

BACKGROUND

Face masks are commonly used to prevent airborne transmission of pathogens by covering a wearer's mouth and nose, acting as a barrier against aerosols and respiratory droplets. They are also used as protection against air pollution and particulates,

Surgical masks, respirators, and cloth masks are each examples of face masks used for such a purpose. In use, air passes one way through the mask when the wearer inhales and then in reverse hack through the mask when exhaling. When worn correctly, face masks reduce the amount of toxic matter that can pass through from the environment to the wearer (e.g. when inhaling) and that which passes through from the wearer to the environment (e.g. when exhaling), while still providing the wearer with enough oxygen to breathe comfortably.

However, existing face masks do not stop all contamination as pathogens and other toxic matter can still be transferred to a user's lungs. While some pathogens are captured on the exterior of the mask these can then incubate in the mask and multiply, thereby increasing the likelihood of transmission. Continued use of the face mask further increases the risk of incubation and transmission as a user's breathing will saturate the mask with moisture

Substitute Specification, Clean over time and bring the temperature closer to 35° C.-36° C., ideal conditions for pathogen incubation.

Therefore, there is a need for an improved face mask that addresses these problems.

SUMMARY

According to an aspect of the invention, there is provided a face mask comprising: a body defining an interior side and an exterior side of the face mask; a one-way inlet valve that only allows gas to pass from the exterior side of the body to the interior side; and a one-way outlet valve that only allows gas to pass from the interior side of the body to the exterior side.

By providing a face tuask in this manner the invention separates the flow of gas into and out of the face mask, avoiding moisture accumulation around the entrance to the mask and reducing the likelihood of contamination.

The body of the face mask defines an interior side and an exterior side of the mask. The interior side of the mask faces the user when worn correctly, while the exterior side of the mask faces away from the user. These “interior” and “exterior” references are also used to describe other features of the mask. A first component is generally referred to as being on the interior of a second component if it is closer to the face of the user than the second feature is.

The terms “air” and “gas” are used interchangeably throughout the application and are generally intended to refer to the (mixture of) gas in the environment around the user that is inhaled or exhaled while breathing. It will be apparent to the reader that the composition of gasses may change with the surrounding environment and use of the tuask,

The face mask is configured to cover the nose and mouth of a user and may also be configured to cover the eyes of the user.

The face mask may futher comprise: an inlet filter arranged at the inlet valve, the inlet filter comprising an inlet antimicrobial element; and an outlet filter arranged at the outlet valve, the outlet filter comprising an outlet antimicrobial element.

In this way, the filters and antimicrobial elements prevent toxic matter from entering the interior of the mask through the inlet valve or from exiting the interior of the mask through the outlet valve. In addition, they also prevent pathogens incubating on the mask the valves. Optionally, an antimicrobial coating may also be applied to other areas of the face mask such as the body.

Preferably, the antimicrobial element comprises copper or a copper alloy such as brass, bronze, or cupronickel.

In some examples of the invention, the inlet antimicrobial element is the same as the outlet antimicrobial element.

The outlet filter may have a higher gas flow rate than the inlet filter. This helps to ensure the mask provides an efficient flow of gas as the user breathes, reducing the build-up of exhaled breath within the interior of the mask. Similarly, the outlet valve may have a higher gas flow rate than the inlet valve.

The face mask may further comprise an outlet chamber defined by the outlet valve and the outlet filter such that, in use, exhaled gas may pass from the interior side of the face mask into the outlet chamber before passing to the exterior side of the face mask.

The face mask may further comprise a nitrogen adsorption element. The nitrogen adsorption element is arranged near the inlet valve and/or the inlet fitter. In this way, nitrogen from the surrounding air is retained by the nitrogen adsorption element so that air which passes through to the interior of the mask has an increased proportion of oxygen.

For example, the nitrogen adsorption element may be included in the inlet filter or may be a coating on the inlet valve. Preferably, the nitrogen adsorption element is zeolite, activated carbon, or a molecule sieve.

The outlet valve may be a first outlet valve and the mask further comprises a second outlet valve configured to release nitrogen to the exterior side of the mask.

The inlet filter may comprise an inlet mesh with a first mesh size. The outlet filter may comprise an outlet mesh with a second mesh size. Optionally, the first mesh size is smaller than the second mesh size, In this way, the flow rate of gas through the outlet mesh is greater than the flow rate of gas through the inlet filter. In art example, the inlet mesh has a 41% open area while the outlet mesh has a 56.6% open area.

Optionally, the inlet valve is arranged at a first end of the body, and the outlet valve is arranged at an opposing second end of the body. Spacing apart the, valves in this manner helps to provide fresh air for a user to breathe through the mask and to prevent the build-up of toxic matter at the valves and filters.

Preferably, in use, the first end is the top of the body and the second end is the bottom of the body. In this way, gravity also contributes to the efficient one-way flow of gas through the mask during use,

The face mask may further comprise: a frame arranged around at least a portion of the perimeter of the body; and a deformable seal on the intetior side of the frame, the deformable seal being configured to form a seal with the face of a timer.

Typically, the frame is rigid and provides a fixed structure to the face mask, improving the strength of the mask and reducing the likelihood of accidental contact with the mask by a user. The frame may cover the full perimeter of the body or just a portions) depending on the design of the face mask and arrangement of other components. The deformable seal provides a comfortable and airtight seal against the headface of the user when worn correctly.

The body of the face mask may comprise a transparent screen. This allows the mask to provide full face protection for the wearer without inhibiting their vision. Optionally, the interior of the screen nxay comprise an anti-mist coating and/or antimicrobial coating. Similarly, the exterior of the screen may comprise a UV-resistant coating and/or anti-scratch coating.

The screen may be moveably C6JE nectedto the body such that, in use, the screen may be moved relative to the body without breaking a seal formed by the deformable seal. This allows a user to teremporarily remove the screen from covering their face without breaking the secure seal. This may be particularly beneficial when a user only intends to remove the screen for a short period of time such as when eating or drinking.

The face mask further comprises a plurality of attachment points for attaching binding elements. Binding elements, such as a headband or car loops, are used to hold the mask securely in place on the headiface of the user.

DETAILED DESCRIPTION

Referring to the figures, a face mask1has a body10that defines an interior side12of the face mask1and an exterior side14of the face mask1. In use, the mask1is worn in front of a user's face, with the interior side12facing the user.

FIGS.1A and1Bshow an example face mask1from an angled perspective.FIG.1Cshows the same example face mask1from top down perspective andFIG.1Dshows the example mask1from a side on perspective,FIG.2shows a portion of the cross-section of the example face mask1fromFIGS.1A-D, whiteFIG.3shows a portion of the cross-section of a different example face mask1.

The body10of the mask1does not allow gas to pass through from the exterior side14to the interior side12or vice versa. When worn correctly, the mask1forms an airtight seal with the face of a user and so the mask1comprises a plurality of valves that allow a user to breathe comfortably while wearing the mask1. These include a one-way inlet valve16that only allows gas to pass from the exterior side14of the body to the interior side12, and a one-way outlet valve18that only allows gas to pass from the interior side12to the exterior side14. In use, a user may draw oxygen rich air through the inlet valve16into the mask1by breathing in and subsequently eject carbon dioxide rich air from the mask1through the outlet valve18and into the surrounding environment.

In this way, the flow of gas into and out of the mask1is separated, as shown inFIGS.2and3where the direction of gas flowing into the mask1(e.g. when the user inhales) is shown by the arrow A, and the direction of gas flowing out of the mask1(e.g. when the user exhales) is shown by the arrow B. As moisture is only created on the interior side12of the mask1during exhale, this defined flow direction of gas prevents moisture accumulating near the inlet valve16and so reduces contamination to the wearer of the mask1

The mask1and valves16,18are configured such that, un use, a positive air pressure is maintained on the interior side12of the mask1relative to the exterior side14. This helps to prevent gas entering the interior side12of the mask if a gap between the user and the mask1is formed by body movement of the user. In addition, it is preferable that the outlet valvei18is configured to allow a higher gas flow rate than the inlet valve16. This helps to ensure an efficient gas flow path through the mask1and reduces the build-up and recycling (i.e. re-breathing) of exhaled gas within the mask1.

Preferably, the inlet valve16and the outlet valve18are spaced apart from each other. For example, the inlet valve16may be ananged at a first end2of the body10while the outlet valve18is arranged at an opposing second end4of the body10. This is shown inFIGS.1A-DandFIG.2where the inlet valve16is at the top of the body10and the outlet valve18is at the bottom of the body10, so that gravity further contributes to the efficient one-way flow of gas through the mask1, preventing residues of exhaled gasses such as carbon dioxide being retained within the mask1.

As shown in the details ofFIGS.2and3, the face mask1may also include antimicrobial filters arranged nearby the valves. To he specific, an inlet filter20is arranged at the inlet valve16and an outlet filter30is arranged at the outlet valve18. The inlet filter20prevents oxic matter Such as particulates and pathogens from passing into the interior12of the mask1, thus improving the quality of air inhaled the wearer, Similarly, the outlet filler30stops the wearer from contaminating their environment by preventing toxic matter from exiting the mask1.

The antimicrobial elements22,32may be selected according to the anticipated use of the mask1. In addition, the inlet antimicrobial element22of the inlet filter20may be different to the outlet antimicrobial element32of the outlet filter30. For example, it is foreseeable that in some scenarios an inlet filter20will need to he effective at filtering a wider range of toxic matter (due to the surrounding environment) than the outlet filter30. Preferably, the antimicrobial elements22,32comprise copper or a copper alloy such as brass, bronze, or cupronickel. Copper ions (Cu2+) carry a double positive charge and react with many pathogens on contact, causing them to denature.

A valve16,18and its corresponding filter20,30may be arranged in either order with respect to each other. For example,FIG.2shows the outlet valve18closer to the interior side12and the outlet filter30closer to the exterior side14, whileFIG.3shows the outlet valve18and outlet filter30reversed. Preferably, the filter is arranged earlier in the gas flow path than its corresponding valve, as shown inFIG.3, so as reduce contamination of the valves.

The face mask1may also include a nitrogen adsorption element24at the inlet filter20. The nitrogen adsorption element24is a catalyst that retains atmospheric nitrogen from air that passes the element24at the inlet filter20, thereby increasing the proportion of oxygen inhaled by a user while breathing. Preferably, the nitrogen adsorption element24is zeolite, activated carbon, ora molecular sieve. The mask1may have a second outlet valve60arranged at the inlet filter20to facilitate the release of nitrogen from the nitrogen adsorption element24back into the surrounding environment.

The inlet and outlet filters20,30may comprise a mesh that allows gas) pass through while preventing the passage of pathogens and other toxic matter. In particular, the inlet filter20has an inlet mesh21while the outlet filter30includes an outlet mesh31. in some examples, the inlet mesh21and the outlet mesh31have the same filtering properties but this is not always the case. For example, the inlet mesh21may have a smaller mesh size than the outlet mesh31so as to provide (or contribute towards) the mask1having a higher gas outflow rate than it does a gas inflow rate. In a specific example, the inlet mesh21has a 41% open area while the outlet mesh has a 56.6% open area. When the filters20,30comprise a mesh, the antimicrobial elements22,32are typically woven through the meshes21,31to ensure that, due to the natural turbulence of gas flow and the mesh configuration, all of the gas particles contact with the antimicrobial elements22,32. Similarly, the nitrogen absorption element24may also he woven through the inlet mesh21and may coat the mesh21.

Note thatFIGS.1A-Ddo not show several of the components such as the valves16,18,60or the filters20,30but instead illustrates gaps in the body1where they are arranged, Optionally, these components may be removed from the mask1and replaced. In the example shown inFIGS.1A-D, the valves16,18,60and filters20,30would be arranged at the open regions at the first end2and the second end4of the mask1.

In some examples of the mask1, a valve and corresponding filter may be arranged so as to define a chamber in the body10between them. For example, the outlet valve18and outlet filter30may be spaced apart to define an outlet chamber34between them. During use, exhaled gas will pass from the interior side12of the face mask1into the outlet chamber34before passing to the exterior side14of the mask1.

While some examples of the mask1(such as the cross-section shown inFIG.3) provide a body10that is flexible and configured to directly fit onto a user's face, in other examples this is not the case.FIG.1A-Dshow a mask1including a rigid frame40arranged around the perimeter of the body10to provide a more permanent structure (helping to avoid accidental contact with the mask1) and add strength to the mask1. The frame49is constructed from plastic or a lightweight metal, such as aluminium, to allow the mask1to be worn for extended periods of time without tiring the user. The frame40may be arranged around the full perimeter of the body10or may only occupy a portion of the perimeter.

In order to ensure the mask1with a frame40is airtight when worn correctly, the mask1includes a deformable seal42on the interior side12of the frame40. Having the seal42comprise a deformable material such as foam means that the mask1can provide a comfortable and secure fit on a user without allowing gas to avoid the valves16,18,60and filters20,30. In some examples of the mask1, the seal42may also act as an evaporator, removing moister from exhaled gas by absorption and subsequent evaporation into the atmosphere. In a similar manner, when the seal42is arranged nearby the nitrogen adsorption element24it may act as the second outlet valve60and release extracted nitrogen back into the surrounding atmosphere.

The body10may also include a transparent screen11so as to provide full face protection or a user without inhibiting their vision.FIG.2shows an example of the cross section of such a mask1(with the deformable seal42not shown). Preferably, the screen11is a flexible material with anti-mist and antimicrobial coatings on the interior side12and a UV resistant coating on the exterior side14. In addition, some masks are configured such that the screen11and the body10or frame40are moveably connected to one another, for example by a hinge at the top of the mask. This allows a user to temporarily remove the screen11from obstructing their face without breaking the secure seal formed by the deformable seal42.

As shown inFIGS.1A-D, the mask1may also include attachment points50. Typically, the attachment points50are arranged at the (periphery of the body10and are used for connect binding elements (not shown) such as a headband or ear ops that hold the mask1securely in place during use.