Patent ID: 12233291

Further aspects and features of the example embodiments described herein will appear from the following description taken together with the accompanying drawings.

DETAILED DESCRIPTION

Various apparatuses, methods and compositions are described below to provide an example of at least one embodiment of the claimed subject matter. No embodiment described below limits any claimed subject matter and any claimed subject matter may cover apparatuses and methods that differ from those described below. The claimed subject matter are not limited to apparatuses, methods and compositions having all of the features of any one apparatus, method or composition described below or to features common to multiple or all of the apparatuses, methods or compositions described below. It is possible that an apparatus, method or composition described below is not an embodiment of any claimed subject matter. Any subject matter that is disclosed in an apparatus, method or composition described herein that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the example embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the example embodiments described herein. Also, the description is not to be considered as limiting the scope of the example embodiments described herein.

It should be noted that terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term, such as 1%, 2%, 5%, or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

Furthermore, the recitation of any numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term “about” which means a variation up to a certain amount of the number to which reference is being made, such as 1%, 2%, 5%, or 10%, for example, if the end result is not significantly changed.

It should also be noted that, as used herein, the wording “and/or” is intended to represent an inclusive-or. That is, “X and/or Y” is intended to mean X, Y or X and Y, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof. Also, the expression of A, B and C means various combinations including A; B; C; A and B; A and C; B and C; or A, B and C.

The following description is not intended to limit or define any claimed or as yet unclaimed subject matter. Subject matter that may be claimed may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures. Accordingly, it will be appreciated by a person skilled in the art that an apparatus, system or method disclosed in accordance with the teachings herein may embody any one or more of the features contained herein and that the features may be used in any particular combination or sub-combination that is physically feasible and realizable for its intended purpose.

Recently, there has been a growing interest in developing new face masks and/or face respirators and/or helmets with smart features or functions.

Respirators and/or face masks used as personal protective equipment to protect a person wearing the mask and/or respirator from airborne particles and liquids contaminating the wearer are described herein. Herein, the term “face mask” is used to refer to a mask that provides a physical barrier and covers a wearer's mouth and nose. Face masks, as used herein, may include loose fitting masks and may also include respirators. The term “respirator” as used herein refers to a device that is designed to provide a physical barrier and cover a wearer's mouth and nose and to have a tight fit providing an air tight seal between the respirator and a user's face. The face masks and respirators described herein protect a confined area of the face mask, also referred to herein as a cavity present between the face mask and the user's face, from air present in the environment (e.g. outside of the cavity of the face mask). To create a seal, the face masks described herein must fit snuggly against the face of the person wearing the face mask (e.g. such that air can only pass between the environment and the cavity defined by the face mask through one or more ports of the face mask and not through a space between a perimeter of the face mask and the wearer's face).

In at least one embodiment, the face masks described herein may be worn for an extended period, which necessitates the face mask being comfortable to wear. Generally, face masks are manufactured in a standard size intended to be used with a wide range of facial shapes and sizes. The expanse of sizes that is required to be accommodated makes it difficult to ensure a proper and comfortable fit to everyone.

In at least one embodiment, the face masks described herein may by custom-fit face masks. For instance, in at least one embodiment, precise facial dimensions of a person intending to wear the face mask can be measured, such as but not limited to by using a photograph provided by the user following predetermined guidelines such as but not limited to distance guidelines (e.g. a predetermined distance between the person's face and the camera) view guidelines (e.g. front view, perspective view, side view, etc.), lighting guidelines and the like.

In at least one embodiment, a method of producing a custom-fit face mask is described herein. The method utilizes a user interface application integrated with a database. In at least one embodiment, a customer installs an application on a device (e.g. a regular smartphone/tablet with a working front camera) and grants the application access to use the device camera. Once the application is installed and the access has been granted, the application is ready to be used.

In at least one embodiment, the user opens the application on their device and is prompted to place the camera in front of their face in such a way that their face properly fits into a frame generated by the application and shown on a display of the device. As soon as the face fits in the frame, the user is asked to click the picture. The application, through artificial intelligence, measures a portion of the user's face (e.g. a height from a point on a person's nose to a point on the person's chin and a width from a point on the user's left cheek to a point on the user's right cheek). The application then calls out our prerecorded database. In at least one embodiment, the prerecorded database may comprise a sample of about 500 users (e.g. 250 males and 250 females) from different demographics (e.g. mainly age and ethnicity). The database includes their measured mask areas (i.e. measured area of face using dimensions from the height from a point on a person's nose to a point on the person's chin and width from a point on the left cheek to a point on the right cheek, as described above). The artificial intelligence then selects the closest dimensions to that of the user from the database and sends the selected dimensions to a manufacturing unit. The manufacturing unit then manufactures the masks as per the dimensions.

In at least one embodiment, the person intending to wear the face mask may provide a face profile such as but not limited to a three-dimensional (3D) image of their face, for instance provided by a laser probe. It should be understood that other similar methods for creating a customized fitting face mask may also be used.

Further, it should be understood that the face masks described herein could also have customized aesthetic options, such as but not limited to being offered in various colors and/or designs (e.g. shapes) which may be selected by the person intending to wear the face mask.

In at least one embodiment described herein, the face mask may include a replaceable filter cartridge providing for the face mask to be used for long periods of time.

Turning to the figures,FIG.1shows a face mask10according to at least one embodiment described herein. Face mask10has a shell11. Shell11has at least one inhale port12. In the embodiment shown inFIG.1, shell11has two inhale ports12. Shell11also has an exhale port13.

Shell11is configured to cover a nose and a mouth of the person. Shell11includes at least a portion thereof having sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask. The portion of shell11having sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask may be made of any appropriate material for blocking passage of air between the environment and a cavity defined by the shell11. For instance, in at least one embodiment, the portion having sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask may be made of a polymer such as but not limited to polycarbonate or a polycarbonate-based polymer.

In the embodiment shown inFIG.1, each inhale port11is positioned on opposed sides of the portion having sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask.

In the embodiment shown inFIG.1, exhale port11is positioned below the portion having sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask.

Face mask10also includes a retaining element such as but not limited to adjustable head straps14as shown inFIG.1. Head straps14may be used by the person wearing the face mask10to sed retain face mask10on their face (e.g. covering their nose and mouth).

FIG.2shows an exploded view of the components of face mask10ofFIG.1. In at least one embodiment, inhale port12has a filter15(e.g. a replaceable filter) and a filter retainer16for retaining the filter15in the inhale port12.

As shown inFIG.2, in at least one embodiment, exhale port13includes a valve17. Valve17mane be a one-way valve, for example, and may provide for air with a cavity defined by the face mask10to pass outwardly from the cavity to the environment and may inhibit air from passing from the environment into the cavity defined by the face mask10. Exhale port13may also include a valve cover18.

In at least one embodiment, face mask10may include a sealing member19, such as but not limited to the sealing member shown inFIG.2. Sealing member19provide for sealing the face mask10with various face shapes and profiles. Sealing member19may be made of any appropriate material for inhibiting the passage of air between the cavity defined by the face mask10and the face of the user, such as but not limited to a polymer material including a silicone-based polymer material.

In at least one embodiment, face mask10may include a retainer ring20such as but not limited to the retainer ring20shown inFIG.2. Retainer ring20snap fits over shell11and holds shell11and/or sealing member19together as one wearable unit. This final product could be an assembly of components in a variety of shapes, sizes and forms in different permutations and combinations. The assembly could also be through co-injections molding of some parts in a final mold.

In at least one embodiment, the face masks described herein may include at least one sensor to detect health information such as but not limited to heart rate, breathing rate, blood oxygen saturation, body temperature, abnormal sneezing and/or coughing by the wearer. In at least one embodiment, the sensor may be incorporated into a chip21of the face mask, such as but not limited to the chip21shown inFIG.3. Chip21may include a data storage element to store data collected by the sensor. Chip21may also include a transmitter configured to receive the data collected by the sensor and transmit the data to a computing device, such as but not limited to a smartphone of the wearer (e.g. the smartphone having, for example, a mobile application stored thereon configured to receive the data transmitted by the chip21). The collected data may be used for health monitoring purposes such as, for example, screening for symptoms before travel (e.g. at airports or the like).

In at least one embodiment, retaining element14may include ear loops22with pads23to retain the face mask on the wearer. One example of these features is shown inFIG.3.

Turning toFIG.4, in at least one other embodiment, the face masks described herein may include ear plugs31. Ear plugs31may be coupled to shell11and may be integrated as part of the face mask or removably attached to the mask.

In at least one other embodiment, the face masks described herein may be removably attached to a protective head cap/face shield or be integrated as one piece with head cap/face shield, such as but not limited to protective head cap41ofFIG.4.

In at least one other embodiment, the face masks described herein may include one or more ultraviolet (UV) lamps51(e.g. ultraviolet-C light emitting diodes (UVC LEDs) positioned within the inhale port(s)12and/or the exhale port13, as shown inFIG.6. In at least one embodiment, the UV lamps51are positioned within the inhale port(s)12adjacent to or in combination with inhale filters52and/or within the exhale port13adjacent to exhale valve53. In at least one embodiment, the UV lamps51may receive power from a battery such as but not limited to battery54ofFIG.6. As shown therein, battery54may be placed externally on the face mask or, alternatively, may be positioned within the face mask. In at least one other embodiment, the UV lamps51may have an intensity that provides for killing any pathogens (e.g. viruses and/or bacteria) in the air that is inhaled through inhale ports12and/or exhaled through exhale ports13. Additionally, the UVC light could be safely exposed to nose and mouth area for additional protection.

In yet in another embodiment, such as but not limited to the embodiment shown inFIG.7, the face masks described herein may include one or more exhaust fans61. Exhaust fans61may be positioned on or adjacent to the inhale port(s)12to transfer air out of the cavity to facilitate breathing and, for example, dispel CO2from the cavity defined by the face mask.

As noted above, the face masks described herein may include one or more filters15. In at least one embodiment, the filters15are positioned with the inhale port(s)12and/or the exhale port13such that air passing through the inhale port(s)12passes through the filter15and likewise air passing through the exhale port13passes through the filter15. One embodiment of a filter15is shown inFIG.8.

In at least one embodiment, the filters15are configured to deactivate a pathogen (e.g. virus and/or bacteria) in the air as the air passes through the filter. In at least one embodiment, the filters15include a non-woven polypropylene material having pores to provide for the passage of air through the filter. In at least one embodiment, the filters15include a non-woven polypropylene material having pores to provide for the passage of air through the filter, the non-woven polypropylene material being coated with a coating material65configured to deactivate a pathogen (e.g. virus and/or bacteria) in the air as the air passes through the filter15.

In at least one embodiment, the coating material65comprises non-toxic ingredients such as but not limited to sodium chloride, ammonium chloride, potassium chloride, diatomaceous earth, and/or copper nanoclusters embedded in ionic liquid (IL@CuNC), and/or other similar ingredients. The ionic liquids of the IL@CuNCs may include but are not limited to cation-based ionic liquids (comprising, for example, one or more of imidazolium, pyridnium, piperidinium, pyrrolidinium, quinolinium, morpholinium, quaternary phosphonium and quaternary ammonium) and anion-based ionic liquids (comprising, for example, one or more of tetrafluoroborte, hexafluorophosphate, methylsulfate, octylsulfate, acesulfame, trifluoromethylsulfonate, halides ions, bis(trifluoromethyl)sulfonylamide, bis(trifluoromethyl) amide, and dicyanamide).

In at least one embodiment, the coating material65may be configured to break an outer protective layer of pathogens in the air, deactivate the pathogens and thereby make them redundant of doing any harm to human beings.

In at least one embodiment, such as the embodiment shown inFIG.9, the face masks described herein may include an audio system71. Audio system71may include a microphone for receiving sound such as but not limited to the voice of the person wearing the face mask, an amplifier for amplifying the received sound and a speaker for transmitted the amplified sound outwardly from the face mask.

In another embodiment, such as but not limited to the embodiment shown inFIGS.10,11and12, the face masks described herein may be coupled to a tiltable face shield90. The tiltable face shield90may be tiltable to one or more angles (seeFIGS.11and12for one exemplary angle) to provide for the wearer to eat and/or drink without fully removing the face shield. Tiltable face shield90may also provide full face splash protection and therefore be suitable for personnel with facial hair.

The tiltable face shield90may also be worn independent of face mask10in comparatively safer social environments.

In another embodiment, a face mask20may cover and protect a wearer's entire face, including their eyes. An example of this type of face mask20is shown inFIGS.13A-13C. Face mask20may have a full envelop around the head of a wearer and be sealed around neck23. This sealing makes it ideal for a person with facial hair. A tiltable sealable clear visor26provides for a wearer to have short breaks for a drink or snack. Replaceable inhale and exhale filter cartridges24are attached to the face mask20. Also, face mask20may include a pressurized air curtain around the head by device14to ensure no contaminated air from ambient environment can enter the inner air envelop.

FIG.14shows another embodiment of a face mask described herein having a body70and an integrated or removable insert71. Removable insert71has sufficient transparency to provide for visual observation of the mouth of the person when the person is wearing the face mask. Body70and/or insert71may be coated with non-toxic ingredients such as but not limited to sodium chloride, ammonium chloride, potassium chloride, diatomaceous earth and/or IL@CuNC (as described above) or the like.

In at least one embodiment, body70and/or insert71may have one or more of the following characteristics: anti-fog, fluid resistant, latex-free, non-sterile and intended for a single-use.

In at least one embodiment, body70and/or insert71may be configured to resist penetration of fluid splatter by using the ASTM F1862 standard (splash resistance/synthetic blood resistance) (e.g. >80 mm Hg).

In at least one embodiment, body70and/or insert71may demonstrate biocompatibility. For instance, in at least one embodiment, body70and/or insert71may be non-cytotoxic (e.g. according to ISO 10993-5) and/or may be non-sensitizing and non-allergenic (e.g. according to ISO 10993-10).

FIG.15shows another embodiment of a face mask80described herein. Face mask80includes one or more proximity sensors81installed thereon. Proximity sensors81may be positioned around the face mask80and be configured to detect the presence of objects within a defined area82extending outwardly from the face mask80by a preselected distance (e.g. 2 meters) and extending 360 degrees around the face mask80. Proximity sensors81may operate in combination with a signaling system to warn the wearer of the mask80if a person enters the defined area82.

While the applicant's teachings described herein are in conjunction with various embodiments for illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments as the embodiments described herein are intended to be examples. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments described herein, the general scope of which is defined in the appended claims.