Patent Publication Number: US-2022226678-A1

Title: Mask

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 62/989,271 filed on Mar. 13, 2020, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     Traditional masks are often designed to conceal a portion of a user&#39;s face, such as the mouth and nasal passage. When the user wears such masks in high risk environments (e.g., hospitals), the mask prevents the user from inhaling air containing bacteria and viruses. 
     SUMMARY OF THE INVENTION 
     The present disclosure relates to a mask assembly, and more particularly to a UV light disinfectant mask assembly. 
     The disclosure provides, in one aspect, a mask assembly including a mask configured to cover a mouth and nasal passage of the user, a valve coupled to the mask and configured to direct air out of the mask assembly, a strap coupled to the mask, and a module removably coupled to the mask and configured to direct air into the mask assembly, wherein the module includes a filter, an ultraviolet chamber, and a light source. 
     The disclosure provides, in another aspect, a mask assembly including a mask configured to cover a mouth and nasal passage of a user, a strap coupled to the mask, a module removably coupled to the mask, and a filter assembly positioned within the module, the filter assembly including a first filter coupled to an external surface of the module, a second filter positioned within the module, a ultraviolet chamber, and a light emitting diode, wherein the light emitting diode and the ultraviolet chamber are operable to disinfect air flowing through the filter assembly. 
     The disclosure provides, in another aspect, a mask assembly including a mask configured to cover a mouth and nasal passage of the user, a valve coupled to the mask and configured to direct air out of the mask assembly, a strap assembly coupled to the mask, the strap assembly including a first strap configured to engage a first portion of the user&#39;s head, and a second strap configured to engage a second portion of the user&#39;s head, a first module removably coupled to the mask and configured to direct air into the mask assembly, the first module including a first filter assembly, and a second module removably coupled to the mask and configured to direct air into the mask assembly, the second module including a second filter assembly. 
     Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a mask assembly in accordance with an embodiment of the invention. 
         FIG. 2  is a front view of the mask assembly of  FIG. 1 . 
         FIG. 3  is a front view of the mask assembly of  FIG. 1 , illustrating a flow path of air flowing through the mask assembly. 
         FIG. 4  is a partially exploded view of the mask assembly of  FIG. 1 . 
         FIG. 5  is an exploded view of a module of the mask assembly of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
       FIGS. 1-5  illustrate a UV light disinfectant mask assembly  10  according to one embodiment of the invention. The UV light disinfectant mask assembly  10  may be secured to a user&#39;s head, around a user&#39;s mouth, allowing the mask assembly  10  to destroy germs or viruses around the mouth and nasal passage. The mask assembly  10  includes a mask  14 , a module assembly  18 , and a strap assembly  22 . When the mask assembly  10  is worn by the user, the mask  14  is preferably positioned over the user&#39;s mouth and nose, and the module assembly  18  is positioned on opposite sides of the mask  18 , resting on the user&#39;s cheeks. 
     Referring to  FIGS. 1-3 , the illustrated mask  14  is shaped to fit over a user&#39;s mouth and nose. As illustrated, the mask  14  is teardrop shaped and includes a first, generally circular, portion  26  shaped to fit over a user&#39;s mouth and a second portion  30  shaped to fit over a user&#39;s nose. The particular shape of the mask  14  should not be considered limiting as other suitable shapes that fit over the user&#39;s mouth and nose are within the scope of the present disclosure. The second portion  30  is generally tapered and includes a rounded edge  34 . In the illustrated embodiments, the mask  14  is constructed of a flexible and transparent plastic material. However, in some embodiments, the mask  14  may be constructed of a rigid material. An inner perimeter  36  of the mask  14  is lined with a cushion  38 , which forms a seal against the user&#39;s face during use, thereby preventing air from unintentionally leaking out of the mask  14 . 
     With reference to  FIG. 4 , the mask  14  further includes a first connector  42  and a second connector  46  positioned on opposite ends of the mask  14 . The first connector  42  is positioned on a first end  26   a  of the first portion  26  of the mask  14 , and the second connector  46  is positioned on a second end  26   b  of the first portion  26  of the mask  14 . The first and second connectors  42 ,  46  are generally cylindrical and are shaped and sized to receive a portion of the module assembly  18  to couple the module assembly  18  to the mask  14 . 
     With reference to  FIGS. 1-4 , the mask  14  includes a valve  50  coupled to a front surface  54  of the mask  14 . The valve  50  is a one-way valve operable to discharge air exhaled from the user out of the mask  14 , to the surrounding environment. The valve  50  is generally cylindrical and includes flanges  58   a ,  58   b ,  58   c ,  58   d  equidistantly spaced around a perimeter of the valve  50 . More specifically, the valve  50  includes a first flange  58   a , a second flange  58   b , a third flange  58   c , and a fourth flange  58   d . Each of the flanges  58   a ,  58   b ,  58   c ,  58   d  are coupled to the strap assembly  22 . 
     Referring to  FIGS. 2-3 and 5 , the module assembly  18  includes a first module  62  and a second module  66 . Each of the modules  62 ,  66  includes a body  70  having a front wall  74 , a back wall  78  opposite the front wall  74 , a top wall  82 , a bottom wall  86  opposite the top wall  82 , and two side walls  90  the extend between the top wall  82  and the bottom wall  86 . In the illustrated embodiment, the modules  62 ,  66  are generally rectangular and the side walls  90  are curved. In alternative embodiments, the modules  62 ,  66  may include different configurations. As will be described in further detail below, an internal chamber  94  of each of the modules  62 ,  66  houses a filter assembly  98 . 
     The top wall  82  of each of the modules  62 ,  66  supports a door  102 . The door  102  is generally rectangular and includes several elongate apertures  106 . The door  102  is positioned on an external filter  110  of the filter assembly  98 , which is positioned on the top wall  82  of the body  70 . The apertures  106  extending through the door  102  allow for air to flow through the door  102  and into the external filter  110 . In the illustrated embodiment, the door  102  is a sealed door having, for example, a gasket extending around an inner perimeter of the door  102  to inhibit fluid and dust ingress. The illustrated door  102  includes a latch  114 . In order to access the external filter  110 , the user may grasp (e.g., pinch) the latch  114 , which disengages the latch  114  from a corresponding hinge  118  on the module  62 ,  66 , thereby allowing the user to pivot the door  102  open about a pivot point  122 . 
     With reference to  FIG. 5 , the filter assembly  98  includes the external filter  110 , an ultraviolet (UV) chamber  126 , and an internal filter  130 . The external filter  110  is positioned on an external surface  82   a  of the top wall  82  of the body  70 , between the top wall  82  and the door  102 . In the illustrated embodiments, the external filter  110  is composed of paper and is replaceable by a user after extended use. However, in some embodiments, the external filter  110  may be composed of different materials or may be permanently installed within the module  62 ,  66 . The external filter  110  is configured to remove airborne dust particles and debris entering the module  62 ,  66  from the environment. 
     With continued reference to  FIG. 5 , the internal chamber  94  of the module  62 ,  66  includes a chassis  134 . The UV chamber  126  is an elongate frame positioned between the top wall  82  and the chassis  134 . More specifically, the UV chamber  126  is seated within the internal chamber  94  and abuts against an internal surface of the top wall  82 . In the illustrated embodiments, the UV chamber  126  is generally rectangular and composed of aluminum. However, the UV chamber  126  may be composed of alternative materials and/or include different shapes and sizes. 
     A printed circuit board (PCB)  138  is positioned between the UV chamber  126  and the chassis  134 , such that the PCB  138  is seated on an upper surface  134   a  of the chassis  134 . The PCB  138  includes a first light source  142  and a second light source  146 , such that each of the light sources  142 ,  146  include one or more light emitting diodes (LEDs). In particular, the first light source  142  is a first LED, and the second light source  146  is a second LED. In other embodiments, the first and second light sources  142 ,  146  may include any number or arrangement of LEDs, which may be mounted to one or more PCBs. The UV chamber  126  includes apertures shaped and sized to receive the first and second light sources  142 ,  146 . Therefore, during operation of the mask assembly  10 , the first and second light sources  142 ,  146  emit light through the UV chamber  126 . The light sources  142 ,  146  emit light within the chamber  126 , thereby forming a high intensity zone capable of killing airborne bacteria and viruses (e.g., biomass particles) found within the air passing through the module  62 ,  66 . 
     The internal filter  130  is seated within the chassis  134 . More specially, the chassis  134  includes a drawer  154  slidably received within the chassis  134 . The drawer  154  is shaped and sized to receive the internal filter  130 . When the internal filter  130  is seated within the drawer  154 , the drawer  154  is positioned within the chassis  134 , and a seal  158  and an O-ring  162  are secured to an edge of the drawer  154 , thereby securing the internal filter  130  within the chassis  134 . In the illustrated embodiments, the internal filter  130  is composed of paper and is replaceable by a user after extended use. However, in some embodiments, the internal filter  130  may be composed of different materials or may be permanently installed within the module  62 ,  66 . The internal filter  130  is configured to remove airborne dust particles and debris entering the module  62 ,  66  from the environment. 
     The bottom wall  86  of each of the modules  62 ,  66  includes a circular port  166 . The port  166  is shaped and sized to fit within the first and second connectors  42 ,  46  on the mask  14 , thereby removably coupling the modules  62 ,  66  to the mask  14 . The connectors  42 ,  46  engage the port  166  in a “snap-fit” configuration. In some embodiments, the modules  62 ,  66  may be removably coupled or permanently coupled to the mask  14  via alternative configurations. 
     With reference to  FIG. 5 , the mask assembly  10  includes a power source  166  positioned within the module assembly  62 ,  66  and electrically coupled to the filter assembly  98  (e.g., the first light source  142  and the second light source  146 ). In the illustrated embodiment, the power source  166  includes a single cell battery. More particularly, the power source  166  is a lithium-ion battery. However, in alternative embodiments, the battery  166  may include different chemistries. The power source  166  is positioned within a battery compartment  170  of the module  62 ,  66  so that the power source  166  can be removed. In the illustrated embodiment, the battery compartment  170  is positioned adjacent to (e.g., behind) the PCB  138 . The battery compartment  170  includes battery terminals electrically coupled to the PCB  138  to provide power from the battery  166  to the light sources  142 ,  146 . In some embodiments, the module  62 ,  66  may include a charging port (e.g., a USB port) electrically connected to the power source  166 . 
     The battery  166  is insertable and removable from the battery compartment  170  by removing the bottom wall  86  of the module  62 ,  66 , which may be pivotally coupled to the battery compartment  170 . Alternatively, the bottom wall  86  may be coupled to the battery compartment  170  in other ways. The battery  166  can be removed for charging, and optionally replaced by a similar battery to allow for continued operation of the module  62 ,  66 . In other embodiments, the battery  166  may not be removable from the body  70 . In yet other embodiments, the battery  166  may be a single-use battery (e.g., an alkaline battery). 
     The module assembly  18  is operable remotely using any suitable communication scheme (e.g., wireless communication scheme, Bluetooth). In some embodiment, Bluetooth may be used to remotely control the module assembly  18  (e.g., turn the filter assembly  98  ON and OFF, thereby turning the first and second LEDs  142 ,  146  ON and OFF, respectively). Alternatively, in some embodiments, the mask assembly  10  includes a control panel for controlling operation of the module assembly  18 . In such embodiments, the control panel includes an actuator (e.g., a button) to operate the module assembly  18 . In still further embodiments, the module assembly  18  may include a light intensity control, which allows a user to increase or decrease the intensity of the light sources  142 ,  146 . 
     With reference to  FIGS. 1-2 and 4 , the strap assembly  22  is removably coupled to the valve  50  and includes a first strap  174 , a second strap  178 , a third strap  182 , a fourth strap  186 , and a securing portion  190 . The straps  174 ,  178 ,  182 ,  186  are removably coupled to the flanges  58   a - 58   d  on the valve  50  and extend away from the valve  50 . The straps  174 ,  178 ,  182 ,  186  are removably coupled to the flanges  58   a - 58   d  via fasteners (e.g., snaps, pins, etc.)  194 . However, in some embodiments, the straps  174 ,  178 ,  182 ,  186  may be permanently coupled to the valve  50 . A distal end  174   a  of the first strap  174  and a distal end  178   a  of the second strap  178  are coupled to and integrally formed with the securing portion  190 . The securing portion  190  is a circular strap shaped and sized to extend around an upper portion of a user&#39;s head, thereby securing the second portion  30  of the mask  14  to the user. The third strap  182  includes a distal, free end  182   a  configured to removably couple to a distal, free end  186   a  of the fourth strap  186 . The third and fourth straps  182 ,  186  may extend (e.g., wrap) around a lower portion of a user&#39;s head, or neck, and the distal ends  182   a ,  186   a  may be coupled together, thereby securing the first portion  26  of the mask  14  to the user. 
     In order to secure the mask assembly  10  to the user, the user first positions the mask  14  against their face such that the first portion  26  covers the user&#39;s mouth and the second portion  30  covers the user&#39;s nose. The user positions the securing portion  190  of the strap assembly  22  around an upper portion of the user&#39;s head, and wraps the third and fourth straps  182 ,  186  around a lower portion of the user&#39;s head and secures the distal ends  182   a ,  186   a  of the third and fourth straps  182 ,  186  together. 
     In order to operate the mask assembly  10 , the user remotely turns the module assembly  18  ON via the communication scheme. Upon actuation of the module assembly  18 , the first and second light sources  142 ,  146  emit light. With reference to  FIG. 3 , as the user breathes in, the air flows through the modules  62 ,  66 . Specifically, the air flows through the top wall  82  and through external filter  110 , the UV chamber  126 , and the internal filter  130 . The air exits the modules  62 ,  66  via the bottom wall  86  and then enters the mask  14  via the first and second connectors  42 ,  46 . The external filter  110  and the internal filter  130  remove airborne dust particles, and the UV chamber  126  and the LEDs  142 ,  146  irradiate germs and bacteria, thereby sterilizing the air. The mask  14  acts as a secondary filter assembly and provides protection against UV light radiation from the UV chamber  126 , enabling a user to safely wear the mask for an extended period of time (e.g., hours). As the user exhales, the air exits the mask  14  and flows through the one-way valve  50 . 
     Various features of the invention are set forth in the following claims.