Patent Description:
<CIT> discloses a face mask comprising a layer of electret treated crimped conjugate fibers and a wettable innermost layer adapted to adsorb water. <CIT> discloses a mask including a mask body having a multilayer structure comprising a water-absorbing sheet and a volatilization suppression filter which prevents the water retention liquid in the water-absorbing sheet from volatilizing from an outer surface of the mask body. <CIT> discloses a super-high-moisture-absorption-and-filtration medical protective mask having a mask body comprising an inner antibacterial layer, a water absorption layer, filtering layers and an outer waterproof-and-breathable layer in sequence from inside to outside. A water-vapor induction strip is attached between the filtering layers and the outer waterproof layer, and the outer waterproof-and-breathable layer corresponding to the water-vapor induction strip is a transparent layer. <CIT> discloses a mask comprising a sliver fiber cloth layer, a hydrophobic fiber layer, a hydrophilic fiber layer, a first antibacterial layer and a porous-type breathable cloth layer, sequentially overlaid from interior to exterior. <CIT> discloses a dustproof mask having a body comprising inner-layer non-woven fabric and outer-layer non-woven fabric arranged opposite to the inner-layer non-woven fabric and connected in a sewn mode. A filter element is arranged in a containing area formed between the inner-layer non-woven fabric and the outer-layer non-woven fabric and comprises a first protection layer, a first antibacterial layer, a filtering layer, a second antibacterial layer and a second protection layer which are stacked in sequence.

The invention is defined in the independent claims, to which reference should now be made. According to an aspect, there is provided a face mask in accordance with claim <NUM>. Advantageous features are set out in the sub claims.

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims.

Embodiments of the disclosure include systems and methods for preventing discomfort for a user wearing a face mask. Dust masks, and other masks that filter harmful substances, may be worn by a variety of users. Air pollution is a serious problem in some countries, such as China, especially in the winter. People may wear respirators or masks when outside for protection. The use of a moisture absorbing material may extend the life of a face mask. If a user is uncomfortable when wearing the mask, the user may discard the mask before it has been exhausted, thus wasting some of the lifetime of the mask. Additionally, users may be more likely to wear a mask, and thus protect themselves from harmful ambient air, if the mask is comfortable. When the moisture is not removed from the mask, the moisture may build up in the filtering material of the mask, increasing the breathing resistance through the material. Additionally, bacteria thrive in warm and damp environments, so a damp mask could contain harmful bacteria. Also, if a user wears glasses, humidity from a mask may mist the user's glasses, reducing visibility. Additionally, water condensation (or moisture build-up) within the mask can allow for bacteria growth in the mask.

Embodiments of the disclosure include a face mask comprising a plurality of layers, wherein at least one layer is an absorbent layer configured to absorb moisture exhaled by the user. The mask also comprises one or more filtration layers configured to filter harmful substances from the air. In the embodiments disclosed herein, the airflow into the mask may pass through both the filtration layer(s) and the absorbent layer(s). In embodiments, the absorbent layer spans the entire inner surface area of the mask.

The absorbent layer comprises a super absorbent fiber (SAF) material. The super absorbent fiber material may have a strong moisture retention capability, and is able to lock the water in the material without rewetting. Therefore, this super absorbent fiber material may keep the inner layer of the mask contacting the user's skin dry, thus increasing the user's wearing comfort.

Referring now to <FIG>, an embodiment of a face mask <NUM> is shown as worn by a user, wherein the face mask <NUM> may comprise a nonwoven fabric material <NUM> and one or more straps <NUM> configured to hold the mask <NUM> against the face of a wearer. In the embodiment shown, the mask <NUM> comprises a flat foldable shape, wherein the mask may be folded flat and unfolded to fit over the face of a user. In other embodiments, the mask <NUM> may comprise a molded cup shape. In some embodiments, the mask <NUM> may comprise an exhalation valve <NUM> configured to allow air exhaled by the user to exit the mask <NUM> while preventing external air from entering the mask <NUM> via the exhalation valve <NUM>. In some embodiments, the mask <NUM> may comprise a nose clip <NUM> configured to secure the mask <NUM> about the nose of a user.

<FIG> illustrates another view of the mask <NUM> (not worn by the user), showing the exterior surface <NUM> of the mask <NUM>.

<FIG> illustrates a cross-section of the mask of <FIG> (as indicated in <FIG>). The cross-sectional view shows the inner surface <NUM> of the mask (configured to contact and/or be located proximate to the face of the user, and outer surface of the mask <NUM>, with the curvature of the rest of the mask as well as other elements shown "behind" the cross-section. In embodiments, the nonwoven fabric material <NUM> of the mask <NUM> comprises a plurality of layers. The mask <NUM> comprises a first layer <NUM> forming an interior surface <NUM> of the mask <NUM>. In some embodiments, the first layer <NUM> may be configured to contact the face of the user. In embodiments, the first layer <NUM> comprises an anti-bacterial material. The mask <NUM> comprises a second layer <NUM> located adjacent to the first layer <NUM>. The second layer <NUM> comprises an absorbent layer configured to absorb moisture exhaled by a user.

The mask comprises a third layer <NUM> located adjacent to the second layer <NUM>. In some embodiments, the third layer <NUM> comprises a waterproof material configured to prevent moisture from the second layer <NUM> from contacting a fourth layer <NUM>. The mask comprises a fourth layer <NUM> located adjacent to the third layer <NUM>. In embodiments, the fourth layer <NUM> comprises a filtration material configured to trap and/or filter one or more harmful substances from the airflow into the mask <NUM>. The mask may comprise a fifth layer <NUM> located adjacent to the fourth layer <NUM>, which may form the exterior surface <NUM> of the mask <NUM>. In some embodiments, the fifth layer <NUM> may comprise a protective cover configured to protect the filtration material of the fourth layer <NUM> from damage. In some embodiments, the fifth layer <NUM> may comprise a hydrophobic material configured to prevent moisture from the environment from passing through the fifth layer <NUM> into the mask <NUM>. This hydrophobic material may also ensure that moisture absorbed by the second layer <NUM> of the absorbent material is only coming from one direction (e.g. from the interior of the mask).

In some embodiments, additional layers of filtration material may be added to the mask <NUM>.

The plurality of layers <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be formed using a variety of methods of forming nonwoven materials. For example, the materials of the layers may comprise one or more of melt-blown nonwoven materials, spunlaid (or spunbond) nonwoven materials, and/or spunlace nonwoven materials. The materials of the layers may be formed and/or combined with one another using techniques known to those of skill in the art. As an example, the materials of the layers may be formed and/or combined with one another using one or more of melt-blown techniques, spunlaid techniques, needle punching (or needle felting), through-air bonding, adhesive bonding, thermal bonding, hydro-entanglement (i.e. spunlace techniques), ultrasonic pattern bonding, and/or chemical bonding.

The formation of the layers may allow airflow through the layers of the nonwoven fabric material <NUM> to the user, while also providing filtration and/or absorption functionality. For example, the fibers of the absorbent material of the second layer <NUM> may be formed such that air may flow through the fibers of the second layer <NUM>, even when moisture has been absorbed by the fibers of the second layer <NUM>.

As a specific example, the first layer <NUM> may comprise a spunlace anti-bacterial material. The second layer <NUM> comprises an absorbent material formed using through-air bonding. The third layer <NUM> comprises a spunbond waterproof material. As a specific example, the fourth layer <NUM> may comprise a melt-blown filtration material. As a specific example, the fifth layer <NUM> may comprise a spunbond nonwoven material. The use of these layers in this combination and configuration may provide improved comfort to the user without compromising the filtration properties of the mask and without significantly increasing the breathing resistance of the mask.

As described above, the third layer <NUM> (of waterproof material) is located between the second layer <NUM> (of absorbent material) and the fourth layer <NUM> (of filtration material). The third layer <NUM> is be configured to prevent any moisture absorbed by the second layer <NUM> from contacting the filtration material of the fourth layer <NUM>, thereby preventing any possible damage to the filtration material.

The absorbent layer <NUM> comprises super absorbent fibers (SAF) combined with low melting point fiber (LMF), and may also comprise polyethylene terephthalate (PET) fibers and/or ethylene-propylene side-by-side (ES) fibers. The details of the ingredients of the absorbent material of the second layer <NUM> are outlined in Table <NUM>. Specifically, the super absorbent fiber comprise sodium polyacrylate fibers.

When compared to typical cotton or spunlace materials, the absorbent material as described above may comprise a higher water absorptive capacity (as defined by the China National Standard for Textiles GB/T <NUM>). For example, the water absorptive capacity of the absorbent material described above may be approximately <NUM>%, while a typical cotton or spunlace material may only have a water absorptive capacity of approximately <NUM>-<NUM>%.

<FIG> illustrates the determined filtration efficiency of a first mask (Solution <NUM>) and a second mask (Solution <NUM>), both comprising an absorbent layer as described above. In the embodiment shown, the first mask may be formed using through-air bonding, while the second mask may be formed using needle punching. The standard target for filtration efficiency (measured in %) may be approximately <NUM>%. As shown in <FIG>, the first mask and the second mask were determined to have filtration efficiencies higher than the <NUM>% target at increasing levels of water absorption ranging from approximately <NUM> grams (g) to approximately <NUM> of water absorbed by the mask.

<FIG> illustrates the determined airflow (or breathing) resistance of the first mask (Solution <NUM>) and the second mask (Solution <NUM>), both comprising the absorbent layer as described above. The graph of <FIG> illustrates the measure breathing resistance in mmH<NUM>O at different levels of water absorption ranging from approximately <NUM> to approximately <NUM> (of water absorbed by the mask). The target maximum breathing resistance may be approximately <NUM> mmH<NUM>O. As shown in <FIG>, while the breathing resistance may increase as more water is absorbed by the mask, the breathing resistance remained below the target maximum except for one example of the second mask (Solution <NUM>) with <NUM> of absorbed water.

The test results shown in <FIG> illustrate that the mask comprising the absorbent material can effectively absorb moisture without negatively impacting the filtration properties of the mask and/or significantly increasing the breathing resistance of the mask.

Additional testing was completed on a mask comprising the configuration of layers described above. Testing was completed at lower temperature (approximately <NUM>-<NUM>), where users wore a traditional mask and a mask comprising the configuration of layers described herein for approximately <NUM> hours in the low temperature environment. After breathing while wearing the masks for the defined time period, the inner surfaces of the masks were observed to check for moisture condensation. The traditional mask (without the absorbent material and/or the described configuration) was observed to have a significant amount of moisture located on the inner surface of the mask. The mask comprising the configuration described herein was observed to have no moisture located on the inner surface of the mask.

Additionally, the moisture absorption capability of the mask comprising the absorbent material (as described herein) while used in lower temperatures (approximately <NUM>-<NUM>) is shown in Table <NUM> below. The dust mask comprising the absorbent material may be able to absorb moisture with weight gain of approximately <NUM>-<NUM> from a user's exhaled breath during approximately <NUM>-<NUM> hour in the low temperature environment (e.g., at <NUM> and at <NUM>).

An example useful for understanding the invention includes a method of absorbing moisture within a face mask while the user is wearing the mask. The plurality of layers of the mask may enable a variety of functions. A method may include allowing airflow to pass through the plurality of layers of the mask from the external environment toward the face of the user. This airflow may pass through all layers (including a layer of absorbent material) before reaching the user. A method may comprise filtering one or more harmful substances from the airflow by at least one layer of filtration material. A method may comprise allowing exhaled air from the user to pass through the at least one layer of absorbent material, and absorbing moisture from the exhaled air by the at least one layer of absorbent material. The method may further comprise, after absorbing moisture from the exhaled air, continuing to allow airflow through the plurality of layers (including the absorbent material) from the external environment toward the face of the user.

Claim 1:
A face mask (<NUM>) comprising:
at least one layer of filtration material (<NUM>) configured to filter one or more harmful substances from the air breathed by a user;
at least one layer of absorbent material (<NUM>) configured to absorb moisture exhaled by the user,
wherein:
the at least one layer of absorbent material (<NUM>) spans an entire inner surface area of the mask (<NUM>);
the mask (<NUM>) is configured to allow air to pass through the at least one layer of filtration material (<NUM>) and the at least one layer of absorbent material (<NUM>);
the at least one layer of absorbent material (<NUM>) comprises super absorbent fibers and low melting-point fibers;
the super absorbent fibers comprises sodium polyacrylate fibers; and
the super absorbent fibers are configured to be combined to form a layer of the mask (<NUM>) via through-air bonding;
at least one layer of waterproof material (<NUM>), located between the at least one layer of filtration material (<NUM>) and the at least one layer of absorbent material (<NUM>), configured to prevent moisture from the absorbent material from contacting the filtration material wherein the at least one layer of waterproof material (<NUM>) comprises a spunbond waterproof material; and
further comprising at least one layer of anti-bacterial material (<NUM>) located adjacent to the at least one layer of absorbent material (<NUM>) and forming the inner surface of the mask (<NUM>).