US-12623097-B2 - Reusable face mask

US12623097B2US 12623097 B2US12623097 B2US 12623097B2US-12623097-B2

Abstract

A reusable face respirator mask for respiratory protection comprising a body dimensioned to fit over a portion of a face of a wearer, including a rigid support component and a flexible seal component molded to the rigid support component, a replaceable filtering element sized and configured to removably cover the rigid support component, and a cover configured to removably couple with the rigid support component of the body. The filtering element is used to filter particles and/or pathogens from inhaled and/or exhaled air. A thumb release located on the cover allows the wearer to decouple the cover to accommodate frequent replacement of the filtering element. The flexible seal component is configured to interface with the face of the wearer and deform under moderate pressure to create a substantially airtight seal with the wearer's face.

Inventors

Kevin Ngo

Assignees

AIR FLO LABS, LLC

Dates

Publication Date: 20260512
Application Date: 20220817

Claims (19)

1 . A reusable respirator mask with a replaceable filtering element, comprising: a body dimensioned to fit over a portion of a face of a wearer, the body comprising a rigid support component and a flexible seal component molded to the rigid support component, wherein the rigid support component comprises a filter facing surface and a wearer facing surface, opposite the filter facing surface; the replaceable filtering element sized and configured to removably cover the filter facing surface of the rigid support component, the replaceable filtering element including a top tab projecting from a perimeter of the replaceable filtering element, and a bottom tab projecting from the perimeter opposite the top tab; a cover configured to removably couple with the rigid support component, the cover comprising an outer surface and an inner surface, opposite of the outer surface; and wherein an edge of the rigid support component includes a first complementary recess and a second complementary recess, and wherein a covering of the replaceable filtering element over the filter facing surface is based on aligning the top tab with the first complementary recess and the bottom tab with the second complementary recess.
2 . The reusable respirator mask of claim 1 , wherein the rigid support component comprises a first material and the flexible seal component comprises a second material that is more flexible than the first material.
3 . The reusable respirator mask of claim 2 , wherein the rigid support component is defined by an outer wall surrounding a plurality of concentric inner walls joined by a plurality of interconnecting ribs, the inner walls defining a plurality of internal openings; and wherein the wearer facing surface forms a cavity around the wearer's face when the mask is worn by the wearer.
4 . The reusable respirator mask of claim 3 , wherein the outer wall comprises a first complementary mating element, and the inner surface of the cover comprises a second complementary mating element, the first complementary mating element and the second complementary mating element being configured to mate with one another in a complementary manner and to allow coupling and decoupling of the cover on the body.
5 . The reusable respirator mask of claim 4 , wherein the mating of the cover and the body is a snap-fit connection.
6 . The reusable respirator mask of claim 4 , wherein the first complementary mating element is a recess, and the second complementary mating element is a protrusion.
7 . The reusable respirator mask of claim 4 , wherein the cover and the body are configured to mate with one another such that the cover is selectively coupled to the body in a first direction to secure the replaceable filtering element between the cover and the body.
8 . The reusable respirator mask of claim 7 , wherein the outer surface of the cover comprises a latch configured to accommodate moving the cover in a second direction opposite the first direction, to allow removal of the cover from the body.
9 . The reusable respirator mask of claim 7 , wherein the cover is configured to be decoupled from the body by lifting a latch in a second direction, opposite the first direction.
10 . The reusable respirator mask of claim 4 , wherein the flexible seal component comprises a side wall and a membrane adapted to seal around the wearer's face, the membrane being connected to the side wall at an outer periphery of the membrane and being unconnected at an inner periphery of the membrane.
11 . The reusable respirator mask of claim 10 , wherein the membrane comprises a nose bridge engagement portion shaped and sized to seal around a nose bridge of the wearer.
12 . The reusable respirator mask of claim 11 , wherein the side wall comprises a pair of recesses each positioned a same distance from a center of the nose bridge engagement portion, the pair of recesses shaped and sized to receive eyeglasses worn by the wearer.
13 . The reusable respirator mask of claim 3 , further comprising a condensation insert removably insertable within the cavity.
14 . The reusable respirator mask of claim 13 , wherein the condensation insert comprises a moisture absorbing material.
15 . The reusable respirator mask of claim 1 , wherein the rigid support component comprises a set of protective enclosures extending around an outer perimeter thereof, the set of protective enclosures configured to secure the replaceable filtering element removably covering the filter facing surface, and the inner surface of the cover includes a set of complementary channels extending within the inner surface, the set of complementary channels of the cover receiving the set of protective enclosures of the rigid support component.
16 . The reusable respirator mask of claim 1 , wherein the cover comprises a first set of anchors and a second set of anchors configured to receive a head attachment mechanism.
17 . The reusable respirator mask of claim 16 , wherein the head attachment mechanism comprises a first strap attached to the first set of anchors, and a second strap attached to the second set of anchors, each strap equipped with an adjustment device for accommodating different head sizes and tensioning preferences of the wearer.
18 . The reusable respirator mask of claim 17 , wherein the first strap and the second strap comprise elastomeric material.
19 . The reusable respirator mask of claim 1 , wherein the replaceable filtering element comprises a woven material.

Description

TECHNICAL FIELD The present disclosure relates generally to personal protective equipment. Specifically, the present application relates to reusable respirator masks for respiratory protection. BACKGROUND Face masks have now become a more common, everyday item. They are useful in preventing the spread of disease, as well as helping with allergies and respiratory issues. Traditionally, face masks have been worn by workers in industrial settings to reduce the inhalation of particulate matters and by health care workers to reduce the spread of harmful pathogens. More recently, in response to the pandemic caused by the novel Coronavirus (“Coronavirus”), health agencies across the world have recommended that healthcare workers and vulnerable individuals wear respirator masks to avoid the contraction of and reduce the spread of the Coronavirus. Even as the pandemic slows down in some parts of the world, health care workers are expected to continue wearing masks most of the time. Not all masks provide the same level of protection. For example, simple cloth face masks are a type of personal protective equipment (PPE) worn on the face. Simple cloth masks and coverings do not form a tight seal around wearer's mouth and nose, thereby limiting their ability to protect from germs that may be in the air, since particles can leak in and leak out around the edges. However, these masks still help to slow the spread of airborne viruses because they offer a barrier that helps keep germs and large particle droplets from reaching other people as you talk, cough or sneeze. By contrast, respirator style masks (another type of PPE) remove contaminants from the air using cartridges, filters or canisters. Most respirator masks include a face seal that seals against the user's face. For example, face seals may include flexible lips, gaskets, cushions, and/or the like that engage in physical contact with the wearer's face to create the seal. Respirator masks come in a large variety of types and sizes, ranging from cheaper, disposable masks to more costly, reusable masks that include replaceable filtration cartridges or cannisters. However, the respirator masks most commonly used by medical professionals and regular users alike are disposable. As these disposable masks make their way into the environment, they are disposed of in landfills and can pollute waterways. Like other plastics, they can also break down into microplastics, i.e., particles smaller than 5 mm. Furthermore, because disposable respirator masks are discarded after use, public health and other government agencies have struggled with maintaining adequate supply of respirator masks, especially in time of pandemic. Finally, some wearers may find respirator masks uncomfortable because of a seal formed between the face seal of the mask and the user's face. Therefore, a need exists for a respirator mask that is lightweight, durable, easy to operate, forms a comfortable seal, is inexpensive, and can be reused. SUMMARY In accordance with one or more embodiments, a reusable face respirator mask can be provided for respiratory protection. In some embodiments, the mask comprises a body dimensioned to fit over a portion of a face of a wearer, a replaceable filtering element, and a cover. The body includes rigid support component and a flexible seal component molded to the rigid support component. The replaceable filtering element is sized and configured to removably cover the rigid support component. The filtering element is used to filter particles and/or pathogens from inhaled and/or exhaled air. The cover is configured to removably cover the rigid support component. A thumb release located on the cover allows the wearer to decouple the cover to accommodate frequent replacement of the filtering element. The flexible seal component is configured to interface with the face of the wearer and deform under moderate pressure to create a substantially airtight seal with the wearer's face. In some embodiments, the rigid support component comprises a first material and the flexible seal component comprises a second material that is more flexible than the first material. The replaceable filtering element comprises a woven material. In some embodiments, the rigid support component is defined by an outer wall surrounding a plurality of concentric inner walls joined by a plurality of interconnecting ribs. The inner walls define a plurality of internal openings. When the mask is worn by the wearer, it forms a cavity around the wearer's face. In some embodiments, the outer wall of the rigid support component comprises a first complementary mating element, and the inner surface of the cover comprises a second complementary mating element and being configured to mate with one another in a complementary manner and to allow coupling and decoupling of the cover on the body. In some embodiments, the first complementary mating element is a recess, and the second complementary mating element is a prot