Patent Description:
A conventional anti-virus mask comprises a mask body and two loop-shaped straps mounted on two opposite ends of the mask body. One of the many functions of the mask is to prevent the distribution and spread of active virus and virus particles into the surrounding air. Because an infected person breathing, coughing or sneezing can spray virus particles into the surrounding air, the spread of such particles can be minimized by an infected person wearing a mask.

When in use, the straps are put on a user's ears, and the mask body is placed over the user's mouth and nose, the mask will stop virus particles from travelling far from the user and infecting another person, as well as preventing the virus particles from touching and entering the user's mouth and nose. It is highly desirable to prevent virus particles from entering the user's mouth and nose as the virus particles cannot survive without a host and can only reproduce by attaching themselves to the user's cells.

Typical masks however may not be able to prevent a virus particle from entering the user's mouth and/or nose, resulting in risk of damage or infection to the user. For example, the particle size of SARS-CoV-<NUM> virus (hereinafter "COVID-<NUM>") ranges from <NUM> to <NUM> microns, i.e., about <NUM> on average. In clinical tests of the ability of different mask types to filter <NUM> particles (ten times smaller than COVID-<NUM>), it was found that <NUM>% of the particles passed through an N95 mask, <NUM>% of particles passed through a surgical mask and a <NUM>% of particles passed through a cotton handkerchief (Langrish et al.

Examples of known masks used to neutralize viruses are found, for example, in <CIT> and <CIT>. Whilst these documents disclose masks with thermal layers heating in order to neutralize viruses, their temperatures are maintained at a relatively low level so as not to burn the wearer of the mask.

Accordingly, there is a literal and figurative gap in protecting users from dangerous bacteria and viruses. It is an object of the invention to provide a mask that minimizes the number of bacteria, virus and fungi particles that travel through the ambient air and reach and enter the user's mouth and/or nose.

Referring to <FIG>, a first embodiment of a mask <NUM> may include an outer layer <NUM>, a biocidal layer <NUM>, a filtering layer <NUM>, and an inner layer <NUM> contacting the user's skin. Mask <NUM> may also have straps <NUM> for strapping mask <NUM> unto the user's head. Preferably straps <NUM> are loop-shaped to facilitate on a user's ears or around the user's head. Persons skilled in the art are referred to US Publication No. <CIT>.

Preferably the outer layer <NUM> is made of a mixed woven fiber cloth to isolate dust and bacteria having a larger size. Preferably, the outer layer <NUM> is provided with an additive, such as a water-repellent agent, a photocatalyst, a nano-silver antibacterial agent, a copper fiber antibacterial material, and the like. Thus, when the outer layer <NUM> is provided with a water-repellent agent, the outer layer <NUM> can enhance the waterproof effect of the mask, and when the outer layer <NUM> is provided with a photocatalyst or a nano-silver antibacterial agent, or antibacterial copper fiber, the outer layer <NUM> can provide a sterilizing effect to neutralize and/or destroy bacteria and viruses.

Outer layer <NUM> may also be made of a heat-moldable fabric, such as a heat-moldable fabric selected from the group consisting of polypropylene, polyester and non-woven cellulose acetate fabric. Such heat-moldable fabrics permit shaping of facial masks with heat or ultrasonic welding according to the present invention. In one embodiment, the heat-moldable fabric comprises polypropylene webbing which traps airborne particles, but is relatively water repellent so that virus-laden droplets are normally not disrupted even if the virus-laden droplets are trapped within the webbing.

Outer layer <NUM> made alternatively be made of a material, such as e-PTFE (expanded polytetra-fluoro-ethylene), TPE (thermoplastic elastomer), TPEE (thermoplastic polyester/polyether elastomer), COC (cyclic olefin copolymer), FRP (fiber reinforced plastic) and the like. Outer layer <NUM> would be provided with pores having a size smaller than that of a dust, water molecule, bacterium and virus to isolate the dust, water molecule, bacterium and virus efficiently so as to prevent the dust, water molecule, bacterium and virus from passing through outer layer <NUM>.

Mask <NUM> may also have a biocidal layer <NUM>. Biocidal layer <NUM> may be a copper mesh layer or a copper plate 105P with holes 105PH. Preferably the holes are between <NUM> and <NUM>. The copper plate 105P may be a flexible plate to ensure the mask <NUM> better conforms to the user's face shape. Persons skilled in the art shall recognize that the copper in biocidal layer <NUM> may not be a pure form of copper, but instead may be phosphate glass fibers impregnated with copper oxide, glass coated with thin films of copper oxide, metallic and copper alloys, or fabric fibers impregnated with copper compounds. Such biocidal layer <NUM> would provide antiviral properties to mask <NUM>.

Mask <NUM> may also have a filtering layer <NUM> made of a common fiber non-woven cloth to provide a ventilating effect and to utilize static electricity to catch bacteria, dust and viruses moving through the mask <NUM>. Preferably the cloth layer is made of non-woven cloth having a filtration rating between N90 and N100.

An inner layer <NUM> may be provided adjacent to filtering layer <NUM> for contacting the user's skin. Preferably inner layer <NUM> is made of cloth. Such layer can provide a warming effect to the user when the ambient environment has a lower temperature.

<FIG> illustrate a second embodiment of a mask <NUM>, where like numerals refer to like parts. All the teachings from the previous embodiment are hereby incorporated. Mask <NUM> may include an outer layer <NUM>, a first thermal layer <NUM>, a biocidal layer <NUM>, a filtering layer <NUM>, a second thermal layer <NUM>, an inner layer <NUM> contacting the user's skin, and straps <NUM>.

As in the first embodiment, mask <NUM> may have biocidal layer <NUM>, with a copper mesh layer or a copper plate 105P with holes 105PH. Preferably the holes 105PH are between <NUM> and <NUM>. A heating wire or thermal pad 105W may thermally contact the copper plate 105P to heat copper plate 105P to a temperature of at least <NUM> degrees Celsius (and preferably at least <NUM> degrees Celsius) to neutralize viruses, such as the COVID-<NUM> virus. Such neutralization may be accomplished by destroying the S2/S-protein of the COVID-<NUM> virus (which may be involved in receptor recognition, viral attachment and entry into cell) (https://www. com/articles/s41401-<NUM>-<NUM>-<NUM>). Alternatively, thermal pad 105W may be used without copper plate 105P. Persons skilled in the art shall recognize that heating/radiation sources other than thermal pad 105W could be used to generate the heat or radiation, such as a power transistor or diode on or with a heat sink, ultraviolet light sources, microwave, induction, etc. Furthermore, it may obviate the need for a separate filtered exhaust.

Referring to <FIG> and <FIG>, a battery pack <NUM> may be attached to mask <NUM>. A user would be able to charge battery pack <NUM> by connecting it to a USB charger. Such battery pack <NUM> could be a pouch battery pack.

Alternatively, battery pack <NUM> may be removably attached to mask <NUM>. Preferably battery pack <NUM> is a power tool battery pack. Persons skilled in the art shall understand that "power tool battery pack" as used herein shall mean a set of rechargeable battery cells <NUM> disposed in a housing <NUM> that for use with a tool that is powered by an electrical motor, such as a drill, circular saw, reciprocating saw, jigsaw, etc. Persons skilled in the art shall recognize that power tool battery pack <NUM> may be the power tool battery packs disclosed in <CIT>,<CIT>, <CIT>and/or <CIT>.

In particular battery pack <NUM> may be electrically connected to thermal pad 105W. In order to ensure that thermal pad 105W is heated to the desired temperature, mask <NUM> preferably has a controller <NUM>, which receives a signal representative of the temperature of thermal pad 105W from temperature sensor <NUM>. Controller <NUM> can then adjust the amount of current received by thermal pad 105W by controlling a transistor <NUM> using a PWM current control technique. Controller <NUM> can also adjust the temperature of thermal pad 105W dependent upon the input provided by the user via the temperature input buttons <NUM>. Persons skilled in the art will recognize that it is preferable to ensure that thermal pad 105W is heated to a minimum temperature threshold, and that the user can adjust the temperature of thermal pad 105W higher than such temperature threshold.

Persons skilled in the art shall recognize that it may be advantageous to have an air pressure sensor <NUM> to sense the air pressure between the mask <NUM> and the user's face. The air pressure sensor <NUM> can provide such pressure information to controller <NUM>, which can use this information to increase or decrease the temperature of thermal pad 105W or increase the speed of a thermoelectric cooler <NUM> (as described below) depending upon the increased or decreased pressure caused by the user's respiration.

Controller <NUM> preferably controls display <NUM>. Display <NUM> preferably shows the temperature of thermal pad 105W and/or signals whether mask <NUM> is ready for use by providing a color signal, such as displaying "red," "yellow," and "green" colors meaning "not ready," "almost ready" and "ready for use," respectively.

Persons skilled in the art shall recognize that battery pack <NUM> may also be provided with a belt clip so that the user would not have to carry the battery pack <NUM> on mask <NUM>. Instead a cable (not shown) extending between battery pack <NUM> and mask <NUM> would be provided to electrically connect battery pack <NUM> and mask <NUM>.

Persons skilled in the art shall recognize that plate 105P may be connected to the positive output of battery cells <NUM> to electrically charge plate 105P with a positive charge, as shown in <FIG>. Because the COVID-<NUM> particles are negatively charged, they will be attracted to the positively-charged plate 105P, minimizing the number of particles that move beyond plate 105P into the user's nose and/or mouth. Alternatively, plate 105P may be connected to the negative output of battery cells <NUM> to electrically charge plate 105P with a negative charge. Because the COVID-<NUM> particles are negatively charged, they will be repelled by the negatively-charged plate 105P, moving such particles away from the user.

Plate 105P may be electrically charged to a high voltage (at least <NUM>-<NUM> volts and preferably at least <NUM> kilovolts) with a high voltage power supply, such as high voltage power supply HVP or power supply control DC described below.

Referring to <FIG>, mask <NUM> may also have thermal layers <NUM>, <NUM> disposed adjacent to outer layer <NUM> and inner layer <NUM>, respectively. Preferably, the thermal layers <NUM>, <NUM> will be made of a thermally insulating material, such as microfiber. Persons skilled in the art will recognize that it is desirable to have thermal layer <NUM> between the outer layer <NUM> and biocidal layer <NUM> to enable the user to comfortably touch outer layer <NUM>. Similarly, it is desirable to have thermal layer <NUM> between the inner layer <NUM> and biocidal layer <NUM> to enable the user's face to comfortably touch inner layer <NUM>.

Alternatively, thermal layer <NUM> may be made of a metal so as to act as cooling heat sink for biocidal layer <NUM>, so that the user does not feel the heat generated by biocidal layer <NUM>.

Persons skilled in the art may recognize that mask <NUM> may attenuate a user's voice when communicating while wearing the mask <NUM>. Accordingly, it is desirable to provide some means for facilitating communications.

Referring to <FIG> and <FIG>, mask <NUM> may have a microphone <NUM>. Controller <NUM> may receive an audio signal from microphone <NUM> and send it to a speaker <NUM> disposed on the mask <NUM>. Speaker <NUM> could be a piezoelectric speaker.

Speaker <NUM> is preferably amplified so that the user can project his or her voice at a louder volume than his or her usual speaking voice. Preferably the user can control the speaker volume using the volume input controls <NUM>. Persons skilled in the art will recognize speaker <NUM> is preferably powered by battery pack <NUM>.

Controller <NUM> can also send the audio signal to a wireless communication module, such as Bluetooth transceiver <NUM>, which can be wirelessly connected to a separate speaker. Persons skilled in the art will recognize Bluetooth transceiver <NUM> is preferably powered by battery pack <NUM>.

To improve the clarity of the amplified user's voice, it may be advantageous to add sound dampening on inner layer <NUM>. Sound dampener <NUM> could be made of fabric, soundproof foam, etc. Preferably the material of sound dampener <NUM> is selected to absorb high and/or low frequencies, e.g., below approximately <NUM> and/or above <NUM>. Persons skilled in the art shall recognize that microphone <NUM> (and/or an additional microphone (not shown)) may sense ambient sound, which can be used by controller <NUM> to generate an opposite sound wave to output to speaker <NUM>. Such opposite sound wave would cancel the ambient sound, improving the clarity of the amplified user's voice.

Referring to <FIG>, mask <NUM> may also carry a small fan <NUM> for blowing away floating droplets near the user as well as for cooling air heated by the user's breath or thermal pad 105W. Persons skilled in the art will recognize fan <NUM> is preferably powered by battery pack <NUM>. The speed of fan <NUM> may be controlled by controller <NUM> based on user input.

Mask <NUM> may also carry a thermoelectric cooler <NUM> for lowering the temperature inside mask <NUM>. Persons skilled in the art will recognize that thermoelectric cooler <NUM> is preferably a Peltier device. Thermoelectric cooler <NUM> is preferably powered by battery pack <NUM>. The temperature of thermoelectric cooler <NUM> may be controlled by controller <NUM> based on user input. Persons skilled in the art shall recognize that a Peltier device can also be used to warm the space inside the mask <NUM>, which could be desirable for a user working in a cold environment.

Persons skilled in the art may recognize that, depending upon the desired use or application of mask <NUM>, it may be desirable to add ribs or seals on the inside of mask <NUM> in order to prevent any air movement between the nose and the mouth within mask <NUM>. Such arrangement can be found in <CIT>.

<FIG> illustrates a powered air-purifying respirator (PAPR) <NUM> , not forming part of the present invention, but incorporating some of the teachings of the previous embodiments. The PAPR <NUM> preferably delivers a volume of purified air at a generally constant flow rate regardless of changes in the configuration of its elements, the operating condition of the system, or the environment in which the apparatus is used. The air flow can be increased when a sensor indicates either increased heat in the chamber or increase in respiration rate during heavier workloads to provide a larger volume of air.

PAPR <NUM> preferably includes an air delivery system having a filter bank <NUM> for removing harmful particulate matter or gas from the air in a particular environment. The filter bank <NUM> is attached to a blower assembly <NUM> by way of fittings <NUM> on a connecting conduit <NUM> from the filter bank to the blower housing <NUM>. A motor <NUM> drives a turbine <NUM> that draws air through the filter bank <NUM> and delivers it by way of a hose <NUM> to a contained wearer environment, such as a face piece, a head piece or a suit <NUM> worn by the user. Voltage to the motor <NUM> is supplied by a battery pack <NUM> through a controller <NUM> that regulates power to the blower motor <NUM> in response to control signal inputs from a microprocessor integrated into the controller <NUM>. The microprocessor monitors a switch <NUM> to determine whether to apply electrical power to the controller <NUM> and motor <NUM>. Persons skilled in the art are referred to <CIT>and <CIT>.

PAPR <NUM> may have a biocidal filter <NUM>, with a copper mesh layer or a copper plate 340P with holes 340PH or a copper nanofibre. Preferably the holes 340PH are between <NUM> and <NUM>. A heating wire or thermal pad 340W may thermally contact the copper plate 340P to heat copper plate 340P to a temperature of at least <NUM> degrees Celsius (and preferably at least <NUM> degrees Celsius) to neutralize viruses. Alternatively, thermal pad 340W may be used without copper plate 340P. Persons skilled in the art shall recognize that heating/radiation sources other than thermal pad 340W could be used to generate the heat or radiation, such as a power transistor or diode on or with a heat sink, ultraviolet light sources, microwave, induction, etc..

Battery pack <NUM> may be connected to thermal pad 340W. In addition, plate 340P may be connected to the positive output of battery pack <NUM> to electrically charge plate 340P with a positive charge. Because the COVID-<NUM> particles are negatively charged, they will be attracted to the positively-charged plate 340P, minimizing the number of particles that move beyond plate 340P into hose <NUM> and ultimately into the user's nose, mouth and/or eyes. Alternatively, plate 340P may be connected to the negative output of battery pack <NUM> to electrically charge plate 340P with a negative charge. Because the COVID-<NUM> particles are negatively charged, they will be repelled by the negatively-charged plate 340P, moving such particles away from the hose <NUM>.

Plate 340P may be electrically charged to a high voltage (at least <NUM>-<NUM> volts and preferably at least <NUM> kilovolts) with a high voltage power supply, such as high voltage power supply HVP or power supply control DC described below.

Persons skilled in the art shall recognize that the arrangement of PAPR <NUM> can be installed in a fully or partially sealed room or building or land, air, sea or space vehicle to provide purified air to such a location. As such, thermal pad 340W and/or plate 340P could be connected to battery pack <NUM> as described above. Alternatively thermal pad 340W and/or plate 340P could be connected to an AC source.

Persons skilled in the art shall recognize that it is desirable to construct mask <NUM> and/or PAPR <NUM> using zero defect or six sigma manufacturing processes and techniques.

<FIG> illustrates a powered air purifier system <NUM> , not forming part of the present invention, but incorporating some of the teachings of the previous embodiments. The air purifier system <NUM> preferably delivers a volume of purified air at a generally constant flow rate regardless of changes in the configuration of its elements, the operating condition of the system, or the environment in which the apparatus is used. The air flow can be increased when a sensor indicates either increased heat in the chamber or increase in respiration rate during heavier workloads to provide a larger volume of air.

Air purifier system <NUM> preferably includes a housing <NUM> enclosing and/or supporting several components, including a blower assembly <NUM>. Blower assembly <NUM> preferably includes an electric fan for moving air along air flow AF. Persons skilled in the art shall recognize that the electric fan in blower assembly <NUM> may be powered by AC, as is well known in the art.

An air processing chamber <NUM> is preferably disposed downstream of blower assembly <NUM>. Processing chamber <NUM> preferably has a plurality of copper plates, including heater plates <NUM> and/or electrostatic plates 415C.

As discussed above, a heating wire or thermal pad may thermally contact the heating plates <NUM> to heat heating plates <NUM> to a temperature of at least <NUM> degrees Celsius (and preferably at least <NUM> degrees Celsius) to neutralize viruses. Such heating wire or thermal pad may be connected to a power supply PS connected to the AC source. Persons skilled in the art shall recognize that heating/radiation sources other than a thermal pad could be used to generate the heat or radiation, such as a power transistor or diode on or with a heat sink, ultraviolet light sources, microwave, induction, etc..

Heating plates <NUM> are preferably undulating and parallel to each other, allowing the air to go through heating plates <NUM>. Heating plates <NUM> may be disposed at a distance of at least <NUM> and preferably less than <NUM> from each other. The airflow through heating plates <NUM> is at least <NUM> cfm (cubic feet per minute), and preferably less than <NUM> cfm (<NUM> cfm = <NUM> liter per minute).

As mentioned above, processing chamber <NUM> may also have electrostatic plates 415C. Preferably one electrostatic plate 415C will be connected to an output of a high voltage power supply HVP to electrically charge electrostatic plate 415C with a positive charge while another electrostatic plate 415C will be connected to ground. Alternatively, one electrostatic plate 415C will be connected to a positive output of the high voltage power supply HVP to electrically charge electrostatic plate 415C with a positive charge while the other electrostatic plate 415C will be connected to a negative output of the high voltage power supply HVP to electrically charge electrostatic plate 415C with a negative charge. Because the COVID-<NUM> particles are negatively charged, they will be attracted to the positively-charged electrostatic plate 415C, minimizing the number of particles that move beyond electrostatic plate 415C (and thus downstream) and ultimately into the user's nose, mouth and/or eyes.

As shown in <FIG>, electrostatic plates 415C may sandwich the heating plates <NUM> therebetween with electrostatic plates 415C and heating plates <NUM> being within air processing chamber <NUM>. Alternatively electrostatic plates 415C may be disposed upstream (relative to air flow AF) from the heating plates <NUM>. Electrostatic plates 415C and heating plates <NUM> may be within air processing chamber <NUM>.

As shown in <FIG>, electrostatic plates 415C may be disposed perpendicularly to air flow AF. It is preferable to connect the first electrostatic plate 415C along air flow AF to a negative potential (i.e., -V) or ground, while connecting the second electrostatic plate 415C along air flow AF to a positive potential (i.e., +V) or ground (if the first electrostatic plate 415C along air flow AF to the negative potential -V).

Preferably electrostatic plates 415C may be porous so as to allow some air flow AF to continue to move towards heating plates <NUM>. The porosity of electrostatic plates 415C may be selected to match the air flow allowed by a standard N95 or KN95 masks.

It is desirable to electrically charge electrostatic plate 415C to a high voltage (at least <NUM>-<NUM> volts and preferably at least <NUM> kilovolts).

High voltage power supply HVP can be used to provide such voltage. High voltage power supply HVP preferably includes a transformer T1 that can convert 120VAC to <NUM>-6000VAC. If necessary, a high voltage multiplier can be disposed to step up the output of transformer T1 to the desired voltage. <FIG> shows a typical high voltage multiplier that can be made with the following components: high voltage capacitors HVC (e.g., <NUM> picofarad, <NUM> kilovolt ceramic doorknob capacitors) and high voltage diodes HVD (e.g., HV03-<NUM><NUM> kilovolt peak inverse voltage (PIV) high voltage diodes).

Alternatively, a battery pack <NUM> (and possibly a power tool battery pack) can be used to provide the charge the electrostatic plates 415C as shown in <FIG>. A switch SW1 can be used to connect battery pack <NUM> to the electrostatic plates 415C, If multiple battery packs <NUM> are used, it may be preferable for switch SW1 to have multiple poles so as to connect multiple battery packs <NUM> to the electrostatic plates 415C simultaneously.

A power supply control DC can be used to control the voltage delivered to electrostatic plates 415C. Persons skilled in the art shall recognize that power supply control DC may also include multiple high voltage capacitors (not shown) connected in parallel for charging, and then connected in series via a switch (not shown) for discharging, as is well known in the art, thus increasing the effective charging potential of electrostatic plates 415C.

The switch SW1 may also be a double throw switch so that it can be used to reverse the polarity of electrostatic plates 415C. By reversing the polarity of electrostatic plates 415C, the negatively charged COVID-<NUM> particles will be repelled by the now-negative electrostatic plate 415C, moving downstream towards heating plates <NUM>. This effectively clears electrostatic plates 415C of any build-up.

Persons skilled in the art shall recognize that the high voltages provided by the power supplies shown in <FIG> may ionize the ambient air within air processing chamber <NUM>. Such ionization is advantageous as it may reduce particulates, microbes and odors.

Air purifier system <NUM> may have a biocidal filter <NUM>, with a copper mesh layer or a copper plate with holes or a copper nanofiber. Preferably the holes are between <NUM> and <NUM>.

Persons skilled in the art shall recognize that the arrangement of air purifier system <NUM> can be a stand-alone unit installed in a fully or partially sealed room or within a central HVAC system of a building or land, air, sea, subsurface or space vehicle to provide purified air to and within such a location.

Persons skilled in the art shall recognize that it is desirable to construct air purifier system <NUM> using zero defect or six sigma manufacturing processes and techniques.

Claim 1:
A mask (<NUM>, <NUM>) comprising:
an outer layer (<NUM>),
a filtering layer (<NUM>), a biocidal layer (<NUM>),
a thermal element (105W), an inner layer (<NUM>) contacting user's skin, and
at least one strap (<NUM>) for securing the mask on the user,
the mask characterised in that the thermal element (105W) heats air to a temperature of at least <NUM> degrees Celsuis.