US-12616857-B2 - Ventilating and filtrating face mask

US12616857B2US 12616857 B2US12616857 B2US 12616857B2US-12616857-B2

Abstract

Aspects herein are directed to a washable and reusable face mask that provides effective filtration of small-sized particulate matter while providing a large surface area for gas exchange. The face mask is formed from knit materials and polyurethane materials and includes a plurality of molded pleats that extend from a right side edge to a left side edge of the face mask.

Inventors

Nick Johnson
Dallas Lund
Kyle Schepke
Chau Yui Fung

Assignees

NIKE, INC.

Dates

Publication Date: 20260505
Application Date: 20220202

Claims (13)

1 . A rigid and washable ventilating face mask comprising: a first laminate construction including a first polyurethane (PU) layer positioned between a first knit layer and a second knit layer, the first knit layer forming an outermost-facing surface of the rigid and washable ventilating face mask; a second laminate construction including a second PU layer positioned between a third knit layer and a fourth knit layer, the third knit layer adjacent to the second knit layer, at least a portion of the fourth knit layer forming an innermost-facing surface of the rigid and washable ventilating face mask; and a molded shape comprising: a right planar portion; a middle planar portion; a left planar portion; and a plurality of molded pleats formed from the first laminate construction and the second laminate construction, the plurality of molded pleats extending continuously from a left side edge to a right side edge of the rigid and washable ventilating face mask, wherein the plurality of molded pleats are heat-set such that the rigid and washable ventilating face mask has structural stability to prevent a collapse of a mid-region of the rigid and washable ventilating face mask against a wearer's nose and mouth when the rigid and washable ventilating face mask is in use.
2 . The rigid and washable ventilating face mask of claim 1 , wherein the third knit layer is substantially unaffixed from the second knit layer.
3 . The rigid and washable ventilating face mask of claim 1 , wherein the first knit layer and the fourth knit layer are mesh knit layers.
4 . The rigid and washable ventilating face mask of claim 1 , wherein the second knit layer and the third knit layer are spacer knit layers.
5 . The rigid and washable ventilating face mask of claim 1 , wherein the first PU layer and the second PU layer include one of an open-cell PU foam or a thermoplastic polyurethane.
6 . The rigid and washable ventilating face mask of claim 1 , further comprising an attachment mechanism adapted to secure the rigid and washable ventilating face mask to a face of a wearer.
7 . The rigid and washable ventilating face mask of claim 1 , wherein the third knit layer and the second PU layer are absent from one or more areas of the rigid and washable ventilating face mask.
8 . A method of manufacturing the rigid and washable ventilating face mask of claim 1 , the method comprising: molding the first laminate construction including the first polyurethane (PU) layer positioned between the first knit layer and the second knit layer to heat-set and form the right planar portion, the middle planar portion, and the left planar portion; and forming the rigid and washable ventilating face mask using the first laminate construction.
9 . The method of manufacturing the rigid and washable ventilating face mask of claim 8 , further comprising: molding the second laminate construction including the second PU layer positioned between the third knit layer and the fourth knit layer; and joining the first laminate construction and the second laminate construction such that the third knit layer is adjacent to the second knit layer and such that a first plurality of molded pleats of the first laminate construction are in registration with a second plurality of molded pleats of the second laminate construction to form the plurality of molded pleats, wherein the first knit layer forms an outermost-facing surface of the rigid and washable ventilating face mask and the fourth knit layer forms an innermost-facing surface of the rigid and washable ventilating face mask.
10 . The method of manufacturing the rigid and washable ventilating face mask of claim 9 , wherein joining the first laminate construction and the second laminate construction includes affixing together a perimeter edge of the first laminate construction and a perimeter edge of the second laminate construction, wherein the middle planar portion is configured to extend at an angle θ from a line extending orthogonal to an axis extending through an apex area of the middle planar portion.
11 . The method of manufacturing the rigid and washable ventilating face mask of claim 9 , further comprising: removing a portion of the second PU layer and the third knit layer at a first area of the rigid and washable ventilating face mask corresponding to an area above a nostril area of a wearer; and removing a portion of the second PU layer and the third knit layer at a second area of the rigid and washable ventilating face mask corresponding to a chin area of the wearer.
12 . The method of manufacturing the rigid and washable ventilating face mask of claim 8 , further comprising affixing an attachment mechanism to the rigid and washable ventilating face mask, wherein the attachment mechanism is adapted to secure the rigid and washable ventilating face mask to a face of a wearer.
13 . The method of manufacturing the rigid and washable ventilating face mask of claim 8 , wherein the rigid and washable ventilating face mask does not include a nonwoven material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application titled, “Ventilating and Filtrating Face Mask,” claims the benefit of priority of U.S. App. No. 63/165,884, filed Mar. 25, 2021, and titled “Ventilating and Filtrating Face Mask.” The entirety of the aforementioned application is incorporated by reference herein. TECHNICAL FIELD Aspects herein relate to a washable, reusable, molded face mask adapted to provide a high degree of filtration of small-sized particulate matter while having a large surface area to facilitate gas exchange in, for example, exercise conditions. BACKGROUND Traditional filtration masks generally use nonwoven materials such as nonwoven polyester fibers, nonwovens with electrostatically charged polypropylene fibers, or nonwovens impregnated with activated charcoal or other additives. Although these materials may provide effective filtration, the materials are unable to withstand washing thus limiting the use-life of the filtration mask. Moreover, traditional filtration masks generally do not have a large surface area making them less than ideal for wear during exercise activity when large amounts of air exchange with the external environment is desired and needed. SUMMARY The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting. Clause 1. A ventilating face mask comprising: at least one knit layer; a filtration layer including one or more of a polyurethane (PU) material and a knit spacer material; and a plurality of molded pleats formed from the at least one knit layer and the filtration layer, the plurality of molded pleats extending continuously from a left side edge of the ventilating face mask to a right side edge of the ventilating face mask. Clause 2. The ventilating face mask according to clause 1, wherein the at least one knit layer is a mesh knit layer. Clause 3. The ventilating face mask according to any of clauses 1 through 2, wherein the PU material includes one of an open-cell PU foam or a thermoplastic polyurethane. Clause 4. The ventilating face mask according to any of clauses 1 through 3, wherein the PU material is positioned between the at least one knit layer and the knit spacer material. Clause 5. The ventilating face mask according to any of clauses 1 through 4, wherein the PU material is bonded to each of the at least one knit layer and the knit spacer material. Clause 6. The ventilating face mask according to any of clauses 1 through 5, further comprising an attachment mechanism adapted to secure the ventilating face mask to a face of a wearer. Clause 7. The ventilating face mask according to any of clauses 1 through 6, wherein the filtration layer does not include a nonwoven material. Clause 8. A ventilating face mask comprising: a first laminate construction including a first polyurethane (PU) layer positioned between a first knit layer and a second knit layer, the first knit layer forming an outermost-facing surface of the ventilating face mask; a second laminate construction including a second PU layer positioned between a third knit layer and a fourth knit layer, the third knit layer adjacent to the second knit layer, at least a portion of the fourth knit layer forming an innermost-facing surface of the ventilating face mask; and a plurality of molded pleats formed from the first laminate construction and the second laminate construction, the plurality of molded pleats extending continuously from a left side edge to a right side edge of the ventilating face mask. Clause 9. The ventilating face mask according to clause 8, wherein the third knit layer is substantially unaffixed from the second knit layer. Clause 10. The ventilating face mask according to any of clauses 8 through 9, wherein the first knit layer and the fourth knit layer are mesh knit layers. Clause 11. The ventilating face mask according to any of clauses 8 through 10, wherein the second knit layer and the third knit layer are spacer knit layers. Clause 12. The ventilating face mask according to any of clauses 8 through 11, wherein the first PU layer and the second PU layer include one of an open-cell PU foam or a thermoplastic polyurethane. Clause 13. The ventilating face mask according to any of clauses 8 through 12, further comprising an attachment mechanism adapted to secure the ventilating face mask to a face of a wearer. Clause 14. The ventilating face mask according to any of clauses 8 through 13, wherein the third knit layer and the second PU layer are absent from one or more areas of the ventilating face mask. Clause 15. A method of manufacturing a ventilating face mask comprising: molding a first laminate