Patent Description:
<CIT> describes a surgical mark a sealing member that reduces or eliminates gaps between the wearer's face and the upper part of the mask by forming a seal between the wearer's face and the mask in use. The mask may include a barrier panel that reduces or prevents the wearer's breath from escaping through the mask and rising to the wearer's eyewear.

<CIT> describes a mask comprising a mask maid body that is a nose cover portion made of a synthetic fibre cloth covering the wearer's nose.

<CIT> describes a mask aimed towards preventing dew condensation on a lens from being caused by leakage of moist exhaled air by making an airspace between a face and the mask as small as possible, and which can be comfortably used without providing a feeling of pressure for a long period of time.

<CIT> describes a cup-shaped filtering face-piece respirator <NUM> that includes a harness <NUM> and a mask body <NUM> that has a multi-layer filtering structure <NUM>.

Aspects and embodiments are generally directed to garments and face masks that an inner portion including a plurality of interior pleats connected to a sealing surface, wherein the sealing surface simultaneously contacts a nose and cheeks of a wearer. The invention is defined in the appended independent claim, with further embodiments described in the dependent claims.

In one example, the plurality of interior pleats is configured to retain a shape of the sealing surface when simultaneously contacting the nose and the cheeks of the wearer.

In another example, the inner portion further comprises a nose wire configured to retain the shape of the sealing surface when simultaneously contacting the nose and the cheeks of the wearer.

In one example, the mask further comprises a first ear loop configured to secure the face mask to a first ear and a second ear loop configured to secure the face mask to a second ear.

In another example, the mask further comprises a first pair of straps configured to be tied together to secure the face mask to a first ear and a second pair of straps configured to be tied together to secure the face mask to a second ear.

Still other aspects, embodiments, and advantages of these exemplary aspects and embodiments are discussed in detail below. Embodiments disclosed herein may be combined with other embodiments in any manner consistent with at least one of the principles disclosed herein, and references to "an embodiment," "some embodiments," "an alternate embodiment," "various embodiments," "one embodiment" or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described may be included in at least one embodiment. The appearances of such terms herein are not necessarily all referring to the same embodiment.

The figures are included to provide illustration and a further understanding of the various aspects and embodiments, and are incorporated in and constitute a part of this specification, but are not intended as a definition of the limits of the disclosure. In the figures, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. In the figures:.

Due to the recent pandemic of the SARS-Cov-<NUM> virus (i.e., Covid-<NUM>), there has been a growing need for face/surgical masks to combat the spread of the virus. To form to the wearer's face while being worn, conventional face masks incorporate the use of pleats around the mouth area of the wear to produce a better fit around the chin of the wearer. However, this design is problematic. The amount of contact between the mask and the area of the face near the bridge of the nose and cheeks is not sufficient, thereby causing humidified air to be expelled through the gaps left near the top of the mask. These gaps not only cause those wearers with glasses to experience their lens fogging up, but the expelled humidified breath of the wearer escapes into the environment. If the expelled breath contains bacteria, viruses, or other contaminants, the effectiveness of the mask is drastically reduced.

Aspects and embodiments offer a solution that reduces the amount of humidified breath escaping toward the eyes and cheeks of the wearer and also provides an overall better seal between the top portion of the mask and the wearer's face, thereby improving the mask's effectiveness compared to prior solutions. Disclosed herein are protective garments and face masks, including medical grade face masks, that utilize internal pleats to provide a better fit around a wearer's face and stopping most air from leaking around the nose.

Referring to <FIG>, a face mask generally indicated at <NUM> is illustrated laying frontside-down on a flat surface <NUM>. The face mask <NUM> includes a body portion <NUM> having an inner surface <NUM>. The body portion <NUM> further has an upper edge <NUM> and a lower edge <NUM>. As shown in <FIG>, the inner surface <NUM> of the body portion includes exterior pleats <NUM>, <NUM>, <NUM> formed horizontally within the body portion. The face mask <NUM> further includes an interior portion <NUM>, which is secured to the inner surface <NUM> of the body portion <NUM> along the upper edge <NUM> of the body portion. The interior portion <NUM> includes interior pleats <NUM>, <NUM> and a sealing surface <NUM>. Each of the interior pleats <NUM>, <NUM> contributes to contact with the interior area of the mask (i.e., not the outside air). As illustrated in <FIG>, the interior portion <NUM> is folded flat like the rest of the face mask <NUM> such that the interior pleats <NUM>, <NUM> are compressed together similar to how the exterior pleats <NUM>, <NUM>, <NUM> are compressed together. This configuration represents the face mask <NUM> being unused and not yet adjusted to conform to a wearer's face.

The face mask <NUM> further includes a first strap <NUM>, a second strap <NUM>, a third strap <NUM> and a fourth strap <NUM> secured to the outer edges of the body portion <NUM>. In the shown embodiment, the face mask <NUM> includes two pairs of straps provided along each outer edges of the body portion <NUM>, with each pair of straps being configured to be tied together to secure the mask <NUM> the face. For example, the first strap <NUM> and the third strap <NUM> provided at one other edge of the body portion <NUM> are configured to be tied together. According to certain examples, the first strap <NUM> and the third strap <NUM> are tied together to secure the mask <NUM> to a first ear of the wearer. The second strap <NUM> and the fourth strap <NUM> are configured to be tied together. According to certain examples, the second strap <NUM> and the fourth strap <NUM> are tied together to secure the mask <NUM> to a second ear of the wearer. It should be understood that other strap configurations may be provided to secure the body portion <NUM> of the face mask <NUM> to the wearer. For example, an elastic loop can be provided on one side of the body portion <NUM> of the face mask <NUM> and an elastic loop can be provided on the other side of the body portion of the face mask. In another example, a first elastic loop is provided on the upper edge <NUM> being connected at each corner thereof and a second elastic loop is provided on the lower edge <NUM> being connected at each corner thereof. Other examples include using hook-and-loop fasteners, strap adjusters, and/or release buckles in place of or in addition to the straps <NUM>, <NUM>, <NUM>, <NUM> discussed above.

To secure the face mask <NUM> to a wearer's face and provide a good seal around the wearer's nose and mouth, the wearer grasps the lower edge <NUM> and pulls it along a path over the wearer's chin along a direction <NUM> (e.g., a first direction). Additionally, to engage the interior portion <NUM>, a wearer grasps the innermost interior pleat <NUM> and pulls the sealing surface <NUM> along the direction <NUM> (e.g., a second direction) towards the nose and cheeks of the wearer. According to certain examples, the first direction is in the -Y/+X/+Z direction relative to the surface <NUM> and the second direction <NUM> is in the +Z direction relative to the surface <NUM>, as illustrated in <FIG>. The angle <NUM> formed by the intersection of the first direction <NUM> and the second direction <NUM>, as shown in <FIG>, is an acute angle (i.e., between <NUM> degrees and <NUM> degrees). Due to the variation of geometry between faces of different people, it is understood that the two directions <NUM>, <NUM> described above will vary within a particular range depending on the particular user. In an example, the acute angle is <NUM> degrees. It is understood that certain examples include the second direction <NUM> being directly towards the face and the first direction <NUM> being the direction needed to secure the lower edge <NUM> beneath the chin.

Referring to <FIG>, the face mask <NUM> illustrated in <FIG> is flipped over. As illustrated in <FIG>, the face mask <NUM> includes an outer surface <NUM> and the outer portions of the exterior pleats <NUM>, <NUM>, <NUM>. The interior portion <NUM> is represented by a dashed rectangle because it is occluded by the outer surface <NUM>.

Referring to <FIG>, a face mask generally indicated at <NUM> is illustrated laying frontside-down on a flat surface <NUM> (e.g., similar to the face mask <NUM> lying front-side down on the flat surface <NUM>). The face mask <NUM> primarily differs from the face mask <NUM> illustrated in <FIG> by including a first elastic ear loop <NUM> and a second elastic ear loop <NUM> in place of the strap configuration. For the sake of brevity, it is understood the description above for the face mask <NUM> is entirely applicable to similar components of the face mask <NUM>. For instance, the face mask <NUM> includes interior pleats <NUM>, <NUM> (e.g., similar to interior pleats <NUM>, <NUM>), an interior portion <NUM> (e.g., similar to the interior portion <NUM>), a body portion <NUM>, and a sealing surface <NUM> (e.g., similar to the sealing surface <NUM>).

Referring to <FIG>, after the wearer has manipulated the face mask <NUM> to conform to the shape around the nose and mouth, the interior portion <NUM> retains its shape, revealing an additional interior pleat <NUM>, which is occluded by the interior pleat <NUM> in <FIG>. The retention of the shape is owed, in some examples to a flexible material used to construct the interior portion <NUM>. In some examples, the interior portion <NUM> is constructed from one or more of foam, cloth, and polypropylene. As illustrated in <FIG>, the interior portion <NUM> is made of the same material as the body portion <NUM>. In one example, the material is cotton. In another example, the material is an open-cell foam with a hydrophobic on its exterior (i.e., the side which is not in direct contact with the wearer's exhalation). In other embodiments, the interior portion <NUM> is constructed with a cloth mixed with an adhesive to add rigidity. In other examples, the interior portion <NUM> is constructed from one or more of the above materials, but also includes a nose wire to impart shape retention capability. Other materials and combinations thereof are contemplated herein. As an alternative to using the nose wire, certain aspects include a crease on each side of the central area of the sealing surface <NUM>, each crease being configured to cause the sealing surface to bend around the nose of the wearer.

Referring to <FIG>, a face mask generally indicated at <NUM> (e.g., similar to the face mask <NUM> and the face mask <NUM>) is illustrated being secured to a wearer's face. For the sake of brevity, the description of similar elements will be omitted. This view of the face mask <NUM> illustrates interior pleats <NUM>, <NUM>, <NUM>, with the interior pleat <NUM> being represented by a dashed line because it is occluded. In certain aspects, one or both of the top pleat <NUM> and the rear pleat <NUM> includes one or more of a flexible wire, strip, or bar constructed from metal or plastic for shape retention. In some embodiments, the metal is aluminum. According to certain aspects, the flexible wire, strip, or bar is constructed from one or more flexible wires that are coated in plastic. In some embodiments, the plastic is a shape-retaining plastic. Examples of the shape-retaining plastic include one of an amorphous thermoplastic, cellulose propionate, TR-<NUM> by CARI STYLE, Ltd. , or an ULTEM resin by SABIC (Saudi Basic Industries Corporation). In one embodiment, only the rear pleat <NUM> includes the flexible metal or plastic described above to retain the shape of the rear pleat as it contacts the nose and cheeks of the wearer. The reduction of metal components in a face mask is beneficial for environments that do not permit certain metals, for example when the mask is in the proximity of an MRI machine. <FIG>, <FIG>, and <FIG> illustrate schematic cross-sectional side views of face masks that highlight a profile of pleats relative to a wearer's face. <FIG> illustrates a conventional disposable face mask generally indicated at <NUM> with a first pleat <NUM>, a second pleat <NUM>, and a third pleat <NUM>. The first pleat <NUM> is configured to rest beneath the nose of the wearer. However, as described above, one problem with the conventional design is that as tension is applied to the first pleat <NUM> to secure the mask to the wearer's face, an interior portion of the mask does not form an adequate seal against the wearer's nose. As a consequence, humid air caused by the wearer's breath escapes along a direction <NUM> towards the wearer's eyes and/or a direction <NUM> along the wearer's cheeks when the mask <NUM> is secured, as illustrated in <FIG>. Whether a nose wire or other mechanism is used to add rigidity to the interior portion of the mask <NUM> that is secured near the nose, there is still no structure capable of reducing the humidity of any air escaping along the directions <NUM>, <NUM>.

<FIG> illustrates an embodiment of a face mask generally indicated at <NUM> (e.g., similar to the face mask <NUM>, the face mask <NUM>, and the face mask <NUM>) including exterior pleats <NUM>, <NUM>, <NUM>, interior pleats <NUM>, <NUM>, <NUM>, and a sealing surface <NUM>. In some examples, each surface of the mask <NUM> forming the interior pleats <NUM>, <NUM>, <NUM> is constructed or coated with a hydrophobic material. In other examples, only the exterior surfaces of the interior pleats <NUM>, <NUM>, <NUM> are coated with the hydrophobic material (i.e. only the surfaces near the nose and not inside the mask <NUM> that is exposed the wearer's breath from the mouth and nose). In other examples, only the interior surfaces (i.e., those surfaces inside the mask <NUM> near the wearer's face) forming the interior pleats <NUM>, <NUM>, <NUM> are coated with the hydrophobic material (i.e., excluding the interior surface connecting the first interior pleat <NUM> and the first exterior pleat <NUM>). In an example, the material is polypropylene. The plurality of interior pleats <NUM>, <NUM>, <NUM>, in addition to any hydrophobic coatings reduces the amount of air that escapes form the mask <NUM> towards the wearer's eyes and/or across the wearer's cheeks, thereby forming a better seal by having more points of contact the bridge of the nose and more contacting area between the surface <NUM> and the nose and cheeks. Additionally, the humidity of any escaping air is greatly reduced, thereby providing anti-fogging benefits.

Those of ordinary skill in the art would understand that variations of the masks <NUM>, <NUM>, <NUM>, and <NUM> described above are contemplated herein. As an example, <FIG> illustrates a face mask generally indicated at <NUM> (e.g., similar to the mask <NUM>) including additional interior pleats <NUM>, <NUM>. The additional interior pleat <NUM> increases the number of points of contact with the bridge of the nose and the mask <NUM> (compared to the face mask <NUM>), and additionally provides more range of customization/adjustment for the wearer. It should be understood that other numbers of interior pleats may be provided to secure a face mask to the wearer. For example, instead of the two additional pleats illustrated in <FIG>, three additional pleats are provided, thereby creating an additional point of contact on the bridge of the nose.

Aspects and embodiments described herein combat transmission of the SARS-Cov-<NUM> virus (as well as other viruses/bacteria) via exhaling by drastically reducing condensation traveling to lenses on glasses (if worn) and forming a better seal with the wearer's face. Certain embodiments are constructed from hydrophobic materials for exterior surfaces, such as polypropylene, and.

hydrophilic materials, such as cotton, that contact the face, thereby providing medical-grade face masks and protective garments. It is understood that the term "protective garment" includes the term "face mask" as well as additional forms of personal protective equipment (PPE).

Certain embodiments of protective garments include one of the face masks <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> described above incorporated into a pair of protective eyeglasses, a medical isolation gown, and/or a face shield, thereby providing increased protection to the wearer. In an example, as an alternative to the face mask <NUM> illustrated in <FIG>, the face mask <NUM> may be attached to a nose support structure of pair of protective glasses or goggles via the rear pleat <NUM>. In another example, one of the face masks <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> is incorporated into the hood of a medical isolation gown (not shown).

Claim 1:
A face mask comprising:
a body portion (<NUM>) including a plurality of exterior pleats (<NUM>, <NUM>, <NUM>) configured to elongate in a first direction (<NUM>) towards a chin of a wearer of the face mask, the body portion having an outer surface and an inner surface; and
an inner portion (<NUM>), characterized in that,
said inner portion (<NUM>) includes a plurality of interior pleats (<NUM>, <NUM>) connected between an upper edge (<NUM>) of the body portion and a sealing surface (<NUM>), the inner portion configured to elongate in a second direction (<NUM>) towards a nose of the wearer at an acute angle from the first direction, wherein the sealing surface simultaneously contacts cheeks and the nose of the wearer in response to the elongation in the second direction.