U.S. patent application number 13/141879 was filed with the patent office on 2011-12-08 for humidification face mask.
Invention is credited to Justin Marc Duveen, Jacobus Terblanche.
Application Number | 20110297152 13/141879 |
Document ID | / |
Family ID | 42170816 |
Filed Date | 2011-12-08 |
United States Patent
Application |
20110297152 |
Kind Code |
A1 |
Duveen; Justin Marc ; et
al. |
December 8, 2011 |
HUMIDIFICATION FACE MASK
Abstract
A self-contained re-humidification mask (1) having locating
means (6) to enable the mask to be supported in an operative
position on a user (4) is provided. The mask has a wall (2) shaped
as a moulded domed mask configured to cover the face of a user from
the nose to the chin. An endless peripheral edge is shaped and
configured to generally anatomically follow the contours of a face
of a user to define, with the face of a user, an air pocket (24).
The mask has a single inlet-outlet aperture (8) located generally
opposite a position occupied in use by a mouth of a user, and at
least one re-humidification assembly (9) located in the
inlet-outlet aperture such that it substantially fills the
aperture. The re-humidification assembly includes a coil (17) of
corrugated hygroscopic paper having an axis of the coil extending
in the direction of fluid flow through the inlet-outlet aperture.
The re-humidification mask preferably has a wall formed from a
non-woven synthetic fibre sheet that is press moulded and heat set
to the domed shape thereof.
Inventors: |
Duveen; Justin Marc; (Cape
Town, ZA) ; Terblanche; Jacobus; (Cape Town,
ZA) |
Family ID: |
42170816 |
Appl. No.: |
13/141879 |
Filed: |
December 9, 2009 |
PCT Filed: |
December 9, 2009 |
PCT NO: |
PCT/IB2009/007695 |
371 Date: |
August 19, 2011 |
Current U.S.
Class: |
128/203.29 |
Current CPC
Class: |
A41D 13/1138 20130101;
A61M 16/0683 20130101; A61M 16/1045 20130101; A61M 16/106 20140204;
A62B 18/02 20130101; A61M 16/1055 20130101; A61M 16/107 20140204;
A62B 23/025 20130101; A61M 16/06 20130101; A62B 9/003 20130101 |
Class at
Publication: |
128/203.29 |
International
Class: |
A61M 16/06 20060101
A61M016/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 11, 2009 |
ZA |
2008/06035 |
Nov 26, 2009 |
ZA |
2009/08408 |
Claims
1. A self-contained re-humidification mask having locating means to
enable the mask to be supported in an operative position on a user,
the mask having a wall shaped as a moulded domed mask configured to
cover the face of a user from the nose to the chin, the mask having
an endless peripheral edge shaped and configured to generally
anatomically follow the contours of a face of a user such that, in
use, the domed shape of the mask defines, with the face of a user,
an air pocket, the mask having a single inlet-outlet aperture
located generally opposite a position occupied in use by a mouth of
a user, and at least one re-humidification assembly located in the
inlet-outlet aperture such that it substantially fills the aperture
and is in open communication with the mouth and nose of the user
and defines a fluid flow passage between the atmosphere and the air
pocket, wherein the re-humidification assembly includes a coil of
corrugated hygroscopic paper having an axis of the coil extending
in the direction of fluid flow through the inlet-outlet
aperture.
2. The re-humidification mask as claimed in claim 1 in which the
inlet-outlet aperture is defined by a squat tubular holder composed
of an inner sleeve and an outer sleeve with each sleeve having an
outwardly directed flange at one end thereof with the periphery of
a hole cut in the mask wall extending between the two flanges so as
to support the tubular holder in the mask and wherein the inner and
outer sleeves have formations for holding the re-humidification
assembly captive within the tubular holder.
3. The re-humidification mask as claimed in claim 1 in which the
mask wall is formed from a non-woven synthetic fibre sheet that is
press moulded and heat set to the domed shape thereof and the
inlet-outlet aperture is located in a hole cut from the mask
wall.
4. The re-humidification mask as claimed in claim 3 in which the
non-woven synthetic fibre sheet contains relatively low and high
melting fibres and the press moulding is carried out at a
temperature selected to cause the low melting fibres to trap the
high melting fibres in the final shape of the wall and wherein the
final wall is gas permeable, at least to a limited extent.
5. The re-humidification mask as claimed in claim 3 or in which the
domed mask is moulded from a non-woven sheet of synthetic fibres
having a weight of from 100 to 150 g/m.sup.2 and the press moulding
is carried out to provide a wall thickness in the range of 0.5 to
3.0 mm.
6. The re-humidification mask as claimed in claim 1 in which the
mask has an endless contoured peripheral edge configured to
yieldingly engage the face of a user with the mask being suitably
rigidly flexible to provide a suitable yielding characteristic.
7. The re-humidification mask as claimed in claim 1 in which the
peripheral edge of the mask has a soft, generally resilient,
endless gasket formation for engagement with a user's face.
8. The re-humidification mask as claimed in claim 1 in which the
operative diameter of the re-humidification assembly is within the
range of 10 to 80 mm.
9. The re-humidification mask as claimed in claim 1 in which the
corrugation height of the corrugated hygroscopic paper is in the
range of 0.1 to 2.5 mm.
10. The re-humidification mask as claimed in claim 1 in which the
re-humidification assembly has an axial dimension in the range of 8
to 25 mm.
11. The re-humidification mask as claimed in claim 1 in which the
re-humidification assembly includes a particle filter including
electrostatic material.
12. The re-humidification mask as claimed in claim 11 in which the
particle filter is suitable for the filtering of bacteria and/or
viruses.
13. The re-humidification mask as claimed in claim 1 in which the
re-humidification assembly includes a pad impregnated with a
medication.
14. The re-humidification mask as claimed in claim 13 whenever
packaged together with a container containing medication for use in
impregnating the pad of the mask.
15. The re-humidification mask as claimed in claim 1 in which the
re-humidification mask is made as a disposable item.
Description
FIELD OF THE INVENTION
[0001] This invention relates to improvements in self-contained
humidification face masks. More particularly the invention relates
to self-contained re-humidification face masks that operate
independently of any respirator equipment.
BACKGROUND TO THE INVENTION
[0002] Painful conditions, such as recovering after nasal surgery
or surgery requiring intubation and other trauma to the nose, mouth
and throat are rendered more painful by breathing within a dried
and cold air environment such as in an air conditioned room.
[0003] Furthermore, travelling in a dry and cold air environment,
such as that of an aircraft, may facilitate the development of
painful conditions of the nose and throat or aggravate existing
conditions. The difficulty of breathing through generally blocked
sinuses is also aggravated by exposure to dry and cold air and it
has been found that a dry air environment increases the likelihood
of infection of the internal passages of the nose and throat.
Therefore, exposure to a dry air environment for extended periods
of time not only exacerbates the pain of surgical trauma to the
nose and mouth of a patient and inhibits the healing thereof, but
also promotes the infection of the healthy nose and throat of a
traveler. Similar comments apply to those with or recovering from
colds and flu particularly when breathing through the mouth is
inevitable especially whilst sleeping.
[0004] Furthermore, medical and industrial workers are increasingly
required to wear masks not only to prevent them from contaminating
patients, food, and/or medical equipment, but also to protect them
from airborne disease. Thus medical and industrial workers are
required to wear protective face masks for extended periods of
time, often while working in air-conditioned or otherwise dry air
environments. Many masks currently used by workers incorporate low
flow rate bacterial and/or viral filters which, while preventing
the passage of microbes through the filter, are difficult and
uncomfortable for a user to breathe through. Furthermore, with time
and the build up of humidity from the user's breath, the integrity
and therefore filtering efficiency of the filters become
compromised and unreliable.
[0005] One type of face mask specifically contemplating the
humidification of the breathing air environment makes use of the
inclusion of a moisturizing pad that is typically saturated with
water before use such that in use the air adjacent the pad is
moisturized to provide a humidifying effect to air inhaled through
the face mask. This type of face mask is described in U.S. Pat. No.
4,941,467 and U.S. Pat. No. 6,375,724 and requires the pad to be
saturated or charged with an external source of preferably sterile
moisture prior to use of the face mask. The retention of this
externally sourced moisture within the vicinity of the face of the
user for extended periods of time introduces the possibility of
contamination of the moisture pad, as the pad remains continually
wet for a period of time during both exhalation and inhalation. A
further difficulty associated with the use of this type of face
mask often includes the gradual cooling of the moisture pad during
use such that although the air to be inhaled is moisturized, it is
not significantly warmer than that of the ambient air, particularly
in relatively colder air environments.
[0006] Another type of face mask such as that described for example
in USRE36165EE1 is contemplated to be useful in cold weather for
the heating and humidifying of inhaled air with previously exhaled
air by passing the air through a highly efficient heat exchanger
disposed within the mask. This heat exchanger is made up of a
multitude of layers of metallic mesh through which the warm exhaled
air passes, heating up the mesh which in turn heats up the incoming
air before it is inhaled. Moisture from the exhaled air then
condenses on the relatively cooler heat exchanging metallic mesh
and humidifies the incoming air. However, this device is designed
for repeated use and it is an object of this device to provide a
humidification device that can be safely washed or sterilized even
in a dish washer.
[0007] U.S. Pat. No. 595,173 describes a re-humidification device
that includes a container having a continuous strip of filter paper
helically rolled so as to entirely fill the space defined by a
cross section of the container. This re-humidification device is
however adapted to fit flight masks which deliver pressurized
respiratory fluids to a user, and is for this reason connected via
various conduits to pressurized respiratory fluids.
[0008] The use of several of the face masks listed above is not
suited for patients that have undergone nasal surgery. Not only are
these masks painful and difficult for a user to comfortably wear
during sleep but they become uncomfortably hot to wear after
extended periods of use and may not maintain satisfactory
engagement with the face of the user during sleep. These masks are
also not suited for use by frequent travelers, as they are bulky
and inconvenient to carry while travelling. Not only are such masks
expensive to manufacture on a large scale for disposable use, but
security personnel may prevent travelers from using masks having
wire or metal mesh incorporated therein.
DEFINITIONS
[0009] In the context of this specification the term
"re-humidification mask" means a mask that extracts moisture from
exhaled air and releases at least some of this moisture by
evaporation into inhaled air.
[0010] The term "self-contained" means that the mask operates in
the absence of a separate supply of moisture such that
humidification of inhaled air occurs by re-humidification.
OBJECT OF THE INVENTION
[0011] It is an object of this invention to provide an alternative
humidification face mask which will operate more efficiently than
those currently available and will, at least partially, alleviate
one or more of the problems mentioned above.
SUMMARY OF THE INVENTION
[0012] In accordance with the invention there is provided a
self-contained re-humidification mask having locating means to
enable the mask to be supported in an operative position on a user,
the mask having a wall shaped as a moulded domed mask configured to
cover the face of a user from the nose to the chin, the mask having
an endless peripheral edge shaped and configured to generally
anatomically follow the contours of a face of a user such that, in
use, the domed shape of the mask defines, with the face of a user,
an air pocket, the mask having a single inlet-outlet aperture
located generally opposite a position occupied in use by a mouth of
a user, and at least one re-humidification assembly located in the
inlet-outlet aperture such that it substantially fills the aperture
and is in open communication with the mouth and nose of the user
and defines a fluid flow passage between the atmosphere and the air
pocket, wherein the re-humidification assembly includes a coil of
corrugated hygroscopic paper having an axis of the coil extending
in the direction of fluid flow through the inlet-outlet
aperture.
[0013] A further feature of the invention provide for the
inlet-outlet aperture to be defined by a squat tubular holder
composed of an inner sleeve and an outer sleeve with each sleeve
having an outwardly directed flange at one end thereof with the
periphery of a hole cut in the mask wall extending between the two
flanges so as to support the tubular holder in the mask and wherein
the inner and outer sleeves have formations for holding the
re-humidification assembly captive within the tubular holder.
[0014] Still further features of the invention provide for the mask
wall to be formed from a non-woven synthetic fibre sheet that is
press moulded and heat set to the domed shape thereof and wherein
the inlet-outlet aperture is located in a hole cut from the mask
wall; for the non-woven synthetic fibre sheet to contain relatively
low and high melting fibres and the press moulding is carried out
at a temperature selected to cause the low melting fibres to trap
the high melting fibres in the final shape of the wall and wherein
the final wall is gas permeable, at least to a limited extent; and
for the domed mask to be moulded from a non-woven sheet of
synthetic fibres having a weight of from 100 to 150 g/m.sup.2 with
the press moulding being carried out to provide a wall thickness in
the range of 0.5 to 3.0 mm, preferably about 1.0 mm.
[0015] The mask preferably has an endless contoured peripheral edge
that is generally non-planar and configured to yieldingly engage
the face of a user with the mask being suitably rigidly flexible or
pliable to provide a suitable yielding characteristic. It is also
preferred that the peripheral edge of the mask has a soft,
generally resilient, endless gasket formation for engagement with a
user's face. The gasket formation is typically of open or closed
cell foam material such as a suitable polyurethane foam or the
like.
[0016] The diameter of the re-humidification assembly is typically
within the range of 10 to 80 mm and preferably within the range of
25-45 mm. The corrugation height of the corrugated hygroscopic
paper is preferably within the range of 0.1 to 2.5 mm and
preferably about 0.5 mm. The re-humidification assembly may have an
axial dimension in the range of 8 to 25 mm preferably about 12
mm.
[0017] In one variation of the invention the re-humidification
assembly may include a particle filter including electrostatic
material which may be suitable for the filtering of bacteria and/or
viruses. It may be made to be suitable for the filtering of
microbes in compliance with any required standard such as the N95,
EN149, or FFP3 standards or lower. The particle filter may be
impregnated with antibacterial and/or antiviral medication such as
silver nitrate.
[0018] In another variation of the invention the re-humidification
assembly may include a pad impregnated with a medication. The
medication may be at least one essential oil such as menthol oil
and a container thereof may be frangible such that the mask may be
impregnated with the medication by a user. The container containing
the medication may be an accessory capable of clipping or screwing
onto the re-humidification mask. A re-humidification mask may be
packaged together with a container containing medication for use in
impregnating a pad of the mask.
[0019] The re-humidification assembly may include hygroscopic paper
such as that sold as a Humid-Vent Filter Light HMEF, cellulose
paper, or the like.
[0020] In order that the invention may be more fully understood one
embodiment and some variations thereof will now be described with
reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the drawings:--
[0022] FIG. 1 is a perspective view of one embodiment of
re-humidification mask according to the invention illustrated in
relation to a user's head that is shown in ghosted lines;
[0023] FIG. 2 is a perspective view of a blank mask wall moulded
and ready for receiving a re-humidification assembly in order to
form the re-humidification mask illustrated in FIG. 1;
[0024] FIG. 3 is an exploded view of the re-humidification assembly
of the embodiment of the invention illustrated in FIG. 1;
[0025] FIG. 4 is a side view of the re-humidification mask
illustrated in FIG. 1;
[0026] FIG. 5 is a sectional side view of the re-humidification
mask illustrated in FIG. 1, in use;
[0027] FIG. 6 is a rear elevation of the re-humidification mask
showing the inside thereof;
[0028] FIG. 7 is a view from the top thereof; and,
[0029] FIG. 8 is a view from the bottom thereof.
DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS
[0030] In the embodiment of the invention illustrated in the
drawings, a disposable, self-contained re-humidification mask,
generally indicated by numeral (1), has a moulded, domed
gas-permeable mask wall (2) of the type configured to be fitted
over the nose and mouth of a user (4) and to extend from the nose
to the chin. The mask is to be held in place by straps (6) that
preferably hook around the ears of the user. The straps could, of
course, also extend around the back of the head the exact
configuration being irrelevant to the present invention. The straps
may be made of any suitable material and may even be lycra or other
hypoallergenic material.
[0031] The mask wall (2) is preferably press moulded to form a
stiffened but rigidly flexible or pliable and thus suitably
yieldable, gas-permeable wall preferably having a wall thickness of
about 1.0 mm. The synthetic fibrous sheet material from which the
mask wall (2) is press moulded has intermixed fibres of different
melting temperatures. A first thermoplastic fibre has a higher
melting temperature than a second thermoplastic fibre and the mask
wall (2) is moulded by pressing and heating the composite non-woven
fibres in a mould to a temperature between that of the two melting
temperatures of the constituent thermoplastic fibres.
[0032] The lower melting fibre therefore melts and binds the first
thermoplastic fibre such that, upon cooling, the sheet is set in
the desired shape of the mask (2) whilst remaining gas permeable.
The fibres may include polyethersulphone (PES) fibres and the sheet
may have a weight of about 120 g/m.sup.2 and a thickness before
moulding in the range of 2.4-3.2 mm. Typically, multiple masks will
be moulded at one time from a single sheet and the mask walls will
be cut from the processed sheet.
[0033] At the time of cutting the mask wall from the sheet, a hole
(8) is simultaneously cut in the mask wall for receiving the
re-humidification assembly generally indicated by numeral (9).
[0034] The hole receives a squat tubular holder (10) composed of an
inner sleeve (11) and an outer sleeve (12) with each sleeve having
an outwardly directed flange (13, 14) at one end thereof, the outer
end in this instance, such that the periphery of the hole cut in
the mask wall extends between the two flanges and is clamped
between them. The inner and outer sleeves may frictionally engage
each other to remain in their operative positions; they may clip
into a cooperating position; or they may be adhesively secured
together. The arrangement is such that the edge of the mask wall
supports the tubular holder in the mask.
[0035] The inner and outer sleeves also have formations in the form
of inwardly directed flanges (15, 16) at opposite ends of the
tubular holder for holding a coil (17) of corrugated hygroscopic
paper of the re-humidification assembly captive within the tubular
holder. The inner and outer sleeves each have a diametrically
extending retainer (18) to retain the coil in its operative
position with a central enlargement (19) that operatively obscures
the axial hole inherently formed at the very centre of the
coil.
[0036] The hygroscopic paper, in this instance, includes
reconstituted hygroscopic paper product. The humidifying assembly
(9) may be a Humid-Vent Filter Light HMEF (Gibeck; Upplands Vaesby,
Sweden) or the like. In this instance, the operative diameter of
the humidifying assembly is 35 mm; the corrugation height 0.5 mm;
and the axial dimension of the humidifying assembly is 10-12 mm. Of
course, the humidifying assembly is typically of low respiratory
resistance. Clearly, the axis of the coil extends in the direction
of fluid flow through the inlet-outlet aperture.
[0037] The mask has an endless contoured peripheral edge that is
generally non-planar and configured to yieldingly engage the face
of a user with the mask being suitably rigidly flexible to provide
a suitable yielding characteristic. This peripheral edge of the
mask has a soft, generally resilient, endless gasket (20) typically
of open or closed cell foam material such as a suitable
polyurethane foam for engagement with a user's face.
[0038] A radially outwardly extending recess (21) is moulded into,
and intersects, the operatively upper endless peripheral edge of
the mask (2) for accommodating the bridge of the nose and thereby
enclosing the nose of a wearer.
[0039] The arrangement is such that, in use, the humidifying
assembly (9) is located opposite and in open communication with the
mouth of the user (4). The humidifying assembly (9) is therefore
positioned substantially in the centre of the rounded dome of the
mask (2).
[0040] In use, the mask (2) is positioned on the face of the user
(4) over the mouth and nose by enclosing the mouth and the bridge
of the nose, part of the cheeks and part of the chin of the user
(4) within the mask. The mask (2) is urged to yieldingly engage the
face and is spaced therefrom to define an air pocket (24) between
the face of the user and the mask (2). The domed mask (2) is
moulded such that, in use, the lips (22) of the user (4) cannot
contact the humidifying assembly (9).
[0041] In use, exhaled air passes through the re-humidification
assembly and, in so doing, relinquishes heat and moisture to the
highly absorbent re-humidification assembly. Inhaled air, on the
other hand, becomes warmed somewhat and humidified by the absorbed
heat and moisture carried temporarily by the re-humidification
assembly.
[0042] As indicated above, the re-humidification assembly may
further include a planar particle filter (25) including
electrostatic material and selected so as to be suitable for the
filtering of selected particles, in particular, microbes such as
bacteria and viruses in compliance with N95, EN149, and/or FFP3
regulation standards. This particle filter may be located adjacent
the coil of corrugated hygroscopic paper (17) within the
re-humidification assembly (9).
[0043] As indicated in FIG. 4, the domed mask may be multi-layered
and may include an outside layer (26) of electrostatic material
suitable for the filtering of microbes such as bacteria and
viruses. A layer (27) of hydrophobic material may be layered on the
inside surface of the mask over the gas-permeable material layer
such that the electrostatic material layer is protected from the
humidity of the user's breath. Alternatively, this hydrophobic
layer may be positioned between the outer electrostatic layer and
the inner gas-permeable layer. A further layer (28) of printable
material may be added to the outside of the mask for aesthetic or
promotional purposes.
[0044] It will be appreciated that many additional features may be
added to the re-humidification mask (1) of the invention. Such
features may include the use of a pad (30) which may be impregnated
with medication such as menthol oil and located in or around the
humidification assembly (12) on the interior of the
re-humidification device (1). A kit may be provided which includes
a self-contained re-humidification device of the invention, a
frangible container containing medication, and a pad. The
medication-impregnated pad may then be inserted or clipped onto the
mask.
[0045] The dome of the re-humidification mask of the invention
defines an air pocket between the mask and the face of the user
that is relatively greater than that provided currently on
competitive devices. The humidifying assembly of the device of the
invention is therefore relatively more remote from the mouth and
nose of the user than is the humidifying assembly of currently
available devices.
[0046] The re-humidification mask of this invention may be
comfortably worn during sleep. It is especially notable that the
soft yet pliable mask and the soft resilient gasket material in
combination with the non-elastic straps make for a most comfortable
experience. The mask has no protuberances that could possible
function as a source of discomfort or even injury.
[0047] Furthermore, unlike currently available masks, the mask of
this invention may be made to be both disposable and self-contained
without requiring an external source of pressurized air, moisture
and conduits associated therewith. It can be made to be
biodegradable in keeping with modern tendencies. The self-contained
nature of the mask of the invention allows for resilient gasket
material in combination with the non-elastic straps make for a most
comfortable experience. The mask has no protuberances that could
possible function as a source of discomfort or even injury.
[0048] Furthermore, unlike currently available masks, the mask of
this invention may be made to be both disposable and self-contained
without requiring an external source of pressurized air, moisture
and conduits associated therewith. It can be made to be
biodegradable in keeping with modern tendencies. The self-contained
nature of the mask of the invention allows for greater ease and
application of use. The invention is also relatively cheaper to
produce than re-humidification masks that are currently
available.
[0049] Importantly, in comparison to currently available masks, the
re-humidification mask of the invention has a high flow rate making
it easier for a user to breathe whilst wearing same. The mask
provided by this invention may therefore be worn over prolonged
periods of time, helping a user to recover from surgical procedures
or whilst travelling on an aircraft or recovering from any ailment
involving a blocked nose and consequent breathing through the
mouth.
[0050] Furthermore, the hygroscopic nature of the corrugated coil
of paper in the mask of the invention may function as a desiccant,
wicking accumulated moisture away from any bacterial and/or viral
filter incorporated into the mask, thereby extending the filtering
efficiency and lifespan of the bacterial and/or viral filter.
* * * * *