U.S. patent number 3,664,335 [Application Number 05/013,507] was granted by the patent office on 1972-05-23 for surgical face mask.
This patent grant is currently assigned to International Paper Company. Invention is credited to Wilfred M. Boucher, John Kurilla, Alice C. Slepp.
United States Patent |
3,664,335 |
Boucher , et al. |
May 23, 1972 |
SURGICAL FACE MASK
Abstract
Disposable surgical face mask comprising a flexible porous pad
capable of covering the nose and the mouth of the wearer, the
flexible porous pad having an inner layer of non-woven fiber
material, an outer layer of non-woven fiber material, and a central
layer of filter material. The three layers are stitched together
along their horizontal and vertical edges. An elastic binding is
secured onto each vertical edge of the flexible porous pad. The
flexible porous pad has a first vertical double pleat structure and
a second vertical double pleat structure. The first and second
vertical double pleat structures are parallel to one another and
are spaced a horizontal distance from one another. Each of the
vertical double pleat structures is formed by folding the flexible
porous pad back on itself a first time and then folding it back on
itself a second time thereby forming a "Z" or reverse "Z." A
flexible nose strip and a foam strip are situated along the upper
horizontal edge of the flexible porous pad. Binding tapes are
stitched into the horizontal edges of the flexible porous pad. The
vertical double pleat structures form a cavity on the inner side of
the flexible porous pad. When the frontal face of the flexible
porous pad is extended outwardly, the vertical double pleat
structures expand and provide a semirigid box structure.
Inventors: |
Boucher; Wilfred M. (Fanwood,
NY), Kurilla; John (Doylestown, PA), Slepp; Alice C.
(Teaneck, NJ) |
Assignee: |
International Paper Company
(New York, NY)
|
Family
ID: |
21760321 |
Appl.
No.: |
05/013,507 |
Filed: |
February 24, 1970 |
Current U.S.
Class: |
128/206.19;
128/863 |
Current CPC
Class: |
A41D
13/1192 (20130101); A41D 13/113 (20130101) |
Current International
Class: |
A41D
13/05 (20060101); A41D 13/11 (20060101); A62b
023/02 () |
Field of
Search: |
;128/141,146,146.2,146.6,139,146.7 ;2/206 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
892,262 |
|
Mar 1962 |
|
GB |
|
1,195,603 |
|
Jun 1965 |
|
DT |
|
871,661 |
|
Jun 1961 |
|
GB |
|
Primary Examiner: Gaudet; Richard A.
Assistant Examiner: Dunne; G. F.
Claims
What is claimed is:
1. A surgical face mask, comprising:
a. a generally rectangular flexible porous pad having a pair of
opposed parallel horizontal edges and a pair of opposed parallel
vertical edges, said pad having an inner layer and an outer layer
of non-woven material and a central layer of filter material, said
layers being secured together along their horizontal and vertical
edges to form said flexible porous pad;
b. a pair of elastic binding elements each having a relaxed length
which is substantially shorter than the vertical dimension of said
pad and each having a distended length substantially equal to the
vertical dimension of said pad, said binding elements each being
secured to a respective vertical edge of said pad while distended
to said distended length thereof so that each of said vertical
edges of said pad will be crimped throughout their lengths upon
relaxation of said elastic binding elements;
c. a pair of spaced parallel vertical pleats in said pad extending
from the top horizontal edge to the bottom horizontal edge of said
pad and defining, respectively, a "Z" configuration and a reversed
"Z" configuration in a plane parallel to said horizontal edges,
said pleats together defining therebetween a configuration adapted
to be popped out into a generally C-shaped vertical cavity
extending substantially from the top horizontal edge to the bottom
horizontal edge of said pad and being semirigid to maintain said
pad away from the wearer's nose and mouth in service; and
d. means for retaining said flexible porous pad over the nose and
mouth of a wearer.
Description
BACKGROUND OF THE INVENTION
Surgical masks should be designed to provide protection against
contamination due to air-borne bacteria and the like. The
requirements for an effective surgical mask are that it minimize or
eliminate the number of air-borne bacteria which are exhaled by the
wearer, and at the same time provide a relatively comfortable face
covering which does not interfere with the actions and visibility
of the wearer.
In order to clean the exhaled and inhaled air effectively, a
surgical face mask should provide a tight fit around the wearer's
nose and mouth. However, it is difficult to obtain an air tight
seal around the periphery of the mask where the mask comes into
contact with the wearer's face without the use of uncomfortable
elastic bindings or rigid members affixed to the outer edges of the
flexible pad. These are likely to cause excessive discomfort to the
wearer.
A surgical face mask should have several characteristics. It should
effectively filter the air which the wearer is inhaling and
exhaling and at the same time permit moisture which the wearer is
exhaling to exit from the mask. If moisture does not exit from the
mask, the mask will become moist and saturated and will tend to
lose its effectiveness. Attempts to provide a surgical face mask
which is capable of cleaning the air passing through it effectively
have resulted in indiscriminate increases in the density of the
filtering material included in the porous pad. Such an increase
will often result in capturing a greater amount of moisture. This
will tend to cause the pad to become excessively saturated, while
at the same time not permitting the carbon dioxide exhaled by the
wearer to be effectively dissipated. This can result in a shortness
of breath and impairment of circulation to the head as well as
other objectionable symptoms.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to flexible disposable surgical face masks
and particularly to disposable surgical face masks having a number
of parallel vertical double pleat structures in the flexible pad
portion of the mask. The flexible porous pad comprises a sandwich
structure of an inner layer of non-woven fiber material and an
outer layer of non-woven fiber material. Intermediate the inner
layer of non-woven fiber material and the outer layer of non-woven
fiber material is a filter mat or cover stock. The three layers
have substantially the same peripheral configuration and are
affixed to one another along their respective edges. The resultant
flexible porous pad is then folded along a set of vertical pleat
lines to form a first vertical double pleat structure and a second
vertical double pleat structure. The first and second vertical
double pleat structures are parallel to one another and are spaced
a horizontal distance from one another. One of the vertical double
pleat structures may be formed by folding a first portion of the
flexible porous pad comprising approximately 80 percent of the
horizontal dimension of the flexible porous pad over the remaining
20 percent of the flexible porous pad, and then folding the 80
percent portion back on itself to yield an overlap along
approximately 10 percent of the horizontal dimension of the
flexible porous pad. A similar operation is repeated in reverse at
the other horizontal end of the flexible porous pad to obtain a
cavity having a "Z" and reverse "Z" pleat configuration at either
horizontal extremity of the cavity.
A strip of elastic binding is secured to each of the two vertical
edges of the flexible porous pad. The elastic binding is secured to
the vertical edges, while the elastic binding is in a stretched
condition. After the binding has been secured to the vertical edges
and allowed to return to its normal length, the elastic binding
will crimp and foreshorten the vertical end of the flexible porous
pad. A flexible nose piece is placed on the upper horizontal edge
of the flexible porous pad and an upper and a lower fiber strip are
stitched onto the upper and the lower horizontal ends of the
flexible porous pad. The upper fiber strip covers the flexible nose
piece and secures it to the flexible porous pad. A foam strip is
affixed to the inner surface of the upper fiber strip. When the
mask is worn, the foam strip is in contact with the bridge of the
wearer's nose.
Because of the pair of vertical double pleat structures, the
effective filtering area of the flexible porous pad is
substantially increased. This is particularly true of the filtering
surface in a substantially direct line with the wearer's nose and
mouth. When the mask is to be worn, the cavity formed by the
vertical double pleat structures and the portion of the flexible
porous pad intermediate the vertical double pleat structures is
pushed outwardly. This provides a box-like cavity for the nose,
while simultaneously maintaining the flexible porous pad at a
distance from the wearer's nose and mouth. Each of the vertical
double pleat structures provides a semi-rigid edge structure which
maintains the cavity in a popped-out condition and aids in
overcoming the tendency of the flexible porous pad to assume a flat
configuration. Maintaining this cavity aids in minimizing the
discomfort which is present when a face mask clings to the wearer's
nose and mouth and thereby impedes effective breathing.
It is an object of this invention to provide a device for
protection against contamination from air-borne bacteria.
It is another object of this invention to provide a means for
protection against air-borne contamination in operating
theaters.
It is a further object of this invention to provide an improved
surgical mask which protects the wearer from contamination from the
patients and protects the patient from contamination from the
wearer.
It is a still further object of this invention to provide a
disposable surgical face mask having a vertical box structure to
increase the effective filtration surface area of the mask.
It is yet another object of this invention to provide a disposable
surgical mask which minimizes the discomfort due to the close
proximity of the flexible porous pad to the nose and mouth of the
wearer.
It is still another object of this invention to provide a surgical
mask which has an effective edge gasket sealing system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view partly in section of a preferred
embodiment of the instant invention;
FIG. 2 is a diagrammatic view partly in section of the internal
configuration of the embodiment of FIG. 1;
FIG. 3 is an external view partly in section of the embodiment of
FIG. 1;
FIG. 4 is a vertical cross-sectional view taken along line 4--4 of
FIG. 2;
FIG. 5 is a frontal view of the embodiment of FIG. 1 showing the
mask being worn;
FIG. 6 is a horizontal cross-sectional view taken along line 6--6
of FIG. 5; and
FIG. 7 is a horizontal cross-sectional view taken along line 7--7
of FIG. 4 .
DETAILED DESCRIPTION OF ONE
PREFERRED EMBODIMENT OF THE INVENTION
Referring now to FIG. 1 there is shown an exploded view of a
disposable surgical mask embodying the invention. A flexible porous
pad 2 is assembled comprising an inner layer 4 of non-woven fiber
material, an outer layer 6 of non-woven fiber material and a center
layer 8 of filter mat or cover stock. The peripheral silhouette of
the inner layer 4 of non-woven fiber material and the outer layer 6
of non-woven fiber material, are substantially similar to one
another. Both are substantially similar to the peripheral
silhouette of the center layer 8 of filter mat or cover stock.
A strip 10 of elastic binding is situated along each one of the
vertical edges of the flexible porous pad 2. The extended length,
"L," of each of the strips 10 of elastic binding is substantially
equal to the dimension of the corresponding vertical edge of the
flexible porous pad 2. A flexible strip 12 is located along one
horizontal edge of the flexible porous pad 2. The flexible strip 12
is comprised of a first wire 14 and a second wire 16. The first
wire 14 and the second wire 16 are substantially parallel to one
another over their entire length, and are covered by a coating 18
of plastic material or other material having flexible properties.
The flexible strip 12 serves as a nose piece which can be shaped to
form compound curves due to its dual wire structure.
A mask strip 20 of non-woven material is secured to each of the
horizontal edges of the flexible porous pad 2. The mask strip 20 of
non-woven fiber material has a length substantially greater than
the horizontal dimension of the flexible porous pad 2 and a width
"W." The mask strip 20 is folded along its longitudinal axis prior
to being secured to a horizontal edge of the flexible porous pad 2.
Folding the mask strip 20 results in a mask strip having an
unchanged length and a width substantially equal to W/ 2. The
resultant mask strip 20 is substantially U-shaped. The inner layer
4 of non-woven fiber material, the outer layer 6 of non-woven fiber
material and the filter mat 8 are encompassed within the U formed
by the mask strip when the mask strip 20 is situated in intimate
contact with one of the horizontal edges of the flexible porous pad
2. A second mask strip 22, substantially similar in configuration
to the mask strip 20 is situated in intimate contact with the other
horizontal edge of the flexible porous pad 2. The inner layer 4,
the outer layer 6 of non-woven fiber material, the filter mat 8,
and the flexible strip 12 are encompassed within the second mask
strip 22.
A strip of foam material 24 is mounted on the innermost surface of
the mask strip 22, the innermost surface of the mask strip 22
corresponding to the inner surface of the mask. The strip of foam
material 24 has a length which is substantially similar to the
horizontal dimension of the flexible porous pad 2 after the pad has
been appropriately folded.
A plurality of parallel, vertical fold lines are located on the
inner layer 4 and the outer layer 6 of non-woven fiber material,
and the center layer 8 of filter mat. A set of fold lines 26A, 28A,
30A and 32A on the inner layer 4 of non-woven fiber material, are
parallel to one another and parallel to the vertical edges of the
flexible porous pad 2. A second set of fold lines 26B, 28B, 30B and
32B are situated on the center layer 8 of filter mat. The fold
lines are parallel to one another and parallel to the vertical
edges of the flexible porous pad 2. A third set of fold lines 26C,
28C, 30C and 32C are situated on the outer layer 6 of non-woven
fiber material and are parallel to one another and parallel to the
vertical edges of the flexible porous pad 2. The fold lines 26A,
26B and 26C are substantially coplanar. The fold lines 28A, 28B and
28C are substantially coplanar. The fold lines 30A, 30B and 30C are
similarly coplanar, and the fold lines 32A, 32B and 32C are also
coplanar.
Looking now at FIG. 2, there is shown a view of the inner surface
of the assembled surgical face mask embodying the invention. The
strip 10 of elastic binding has been secured to the flexible porous
pad 2 by means of a series of stitches 40. The stitches 40 pass
through the flexible porous pad 2 and the strip 10 of elastic
binding while the flexible porous pad 2 is in a flat condition and
the strip 10 of elastic binding has been distended to approximately
three times its normal size. Elastized thread may be employed as an
edge binding rather than a strip 10 of elastic binding. The foam
strip 24 is secured by means of glue or other suitable means to the
inner surface of the upper mask strip 2 of non-woven material. The
foam strip 24 extends over substantially the entire horizontal
length of the flexible porous pad 2. The outer surface of the
assembled surgical mask when the surgical mask is not in use is
best shown in FIG. 3.
Referring now to FIG. 3, there is shown a view of the front surface
of the surgical mask embodying the invention. The front surface of
the surgical mask has a horizontal dimension "F." The horizontal
dimension "F" is measured from one of the vertical edges of the
mask to the other vertical edge of the mask. The distance between
the outermost pleats 28 and 30 on the frontal surface of the
flexible porous pad 2 is approximately F/ 2. Each of the outermost
vertical pleats 28 and 30 is disposed approximately F/ 4 from the
corresponding vertical edge of the flexible porous pad 2. The two
innermost pleats 26 and 32 shown in phantom line in FIG. 3 are
disposed at a distance "A" from one another. Each of the innermost
pleats 26 and 32 is disposed a distance "A" from the next
successive pleat in the flexible porous pad 2. For example, the
inner pleat 32 is disposed a distance "A" from the successive outer
pleat 30 which is the next pleat on the flexible porous pad 2.
Therefore, the frontal surface of the flexible porous pad formed by
the "Z" and reverse "Z" vertical double pleat structure has a
dimension of approximately 3A in the horizontal direction.
Each of the mask strips 20 and 22 envelopes one of the horizontal
edges of the flexible porous pad 2. Each of the horizontal edges of
the flexible porous pad is inserted into the respective U shaped
mask strip 20, 22. Each of the mask strips 20, 22 covers a distance
approximately W/ 2 from each of the horizontal edges of the
flexible porous pad 2 on both the inner surface and outer surface
of the pad. Each of the mask strips 20 and 22 is secured to one of
the horizontal edges of the flexible porous pad 2 by means of
stitching 42. The stitching 42 passes through all three layers 4,
6, 8 of the flexible porous pad 2 and through the nine layers of
the flexible porous pad where the flexible porous pad has been
folded along the fold lines 26A, 28A, 30A and 32A, to achieve the
"Z" and reverse "Z" structure.
Referring now to FIG. 4, there is shown a vertical cross-sectional
view taken along line 4--4 of FIG. 2 of the surgical mask. FIG. 4
best illustrates the structural configuration of the surgical pad
prior to "popping out" the vertical double pleat structures of the
surgical pad. The vertical cross section taken is through one of
the nine ply portions of the flexible porous pad 2 where the
flexible porous pad 2 has been folded back on itself, as was
discussed in conjunction with FIGS. 2 and 3. Each of the vertical
pleat structures when viewed in cross section has a layer
configuration, starting from the innermost layer in the vicinity of
the wearer's face, of the layer 4 of non-woven fiber material, the
center layer 8 of filter mat, the outer layer 6 of non-woven fiber
material, an air space, the outer layer 6 of non-woven fiber
material, the center layer 8 of filter mat, the inner layer 4 of
non-woven fiber material, the inner layer 4 of non-woven fiber
material, the center layer 8 of filter mat, and the outer layer 6
of non-woven fiber material. The upper and lower horizontal edges
of the flexible porous pad 2 in the region of the nine ply
structure of the flexible porous pad 2 are also encompassed by the
mask strips 22 and 20, respectively. The stitching 42 traverses
both sides of each of the mask strips 22 and 20 and also traverses
the entire corresponding nine ply portion of the flexible porous
pad 2.
The proper operational configuration of the surgical mask embodying
the invention is best shown in FIG. 5. When the surgical face mask
is to be worn, the wearer should pop the frontal surface of the
flexible porous pad 2 outwardly to expand both of the vertical
double pleat structures. In order to do this, the frontal surface,
which has a horizontal dimension of approximately 3A, should be
pushed forward and away from the plane of the surgical face mask
when the surgical face mask is lying flat. This will cause the "Z"
structure of each of the vertical double pleat structures to
enlarge. Specifically the angles between successive layers of the
flexible porous pad 2 will become less acute and will approach a
90.degree. angle at the pleat. Preferably, the inner pleat 32 and
the outer pleat 30 will lie in a plane which is transverse to the
frontal surface. The inner pleat 26 and the outer pleat 28 should
also lie above one another in a plane which is substantially
transverse to the frontal surface. The planes formed by each of the
vertical double pleat structures should approach a state of
parallelism between one another. The distance between two of the
successive pleats e.g., 26 and 28 measured along their coplanar
surface should be approximately equal to the distance separating
the pleats when the mask is in a flat condition, e.g. A.
FIG. 6 is a vertical cross-sectional view taken along line 6--6 of
FIG. 5 of the surgical face mask and best exemplifies the shape of
the flexible porous pad 2 after the surgical face mask has been
"popped out." The upper and lower horizontal edges of the inner
layer 4, the outer layer 6 of non-woven fiber material and the
center layer 8 of filter mat are within the "U" formed by the two
opposed sides of each of the mask strips 22 and 20, respectively.
The flexible strip 12 with the inner wires 14 and 16 is situated
intermediate the inner layer 4 of non-woven fiber material and the
inner face of the inner portion of the upper mask strip 22. The
foam strip 24 is overlayed on the outer face of the inner portion
of the upper mask strip 22. The longitudinal axis of the foam strip
24 is substantially parallel to the longitudinal axis of the upper
mask strip 22.
The elastic binding 10 is situated on the inner surface of the
inner layer 4 of the non-woven fiber material. One strip of the
elastic binding 10 is located at each one of the vertical edges of
the flexible porous pad 2. Each one of the strips of elastic
binding 10 is stitched into one of the vertical edges of the
flexible porous pad 2. The elastic binding 10, when in a relaxed
state, is approximately one-third to one-half the length of one of
the vertical edges of the flexible porous pad 2. The elastic
binding 10 is distended prior to being stitched into each of the
vertical edges of the flexible porous pad 2. After each one of the
elastic bindings 10 is stitched into one of the vertical edges of
the flexible porous pad 2 the force distending each of the elastic
bindings 10 is released. After the force distending each of the
elastic bindings 10 is released, each of the vertical edges of the
flexible porous pad 2 will become crimped due to the tension
exerted on each of the vertical edges of the flexible porous pad 2
by each of the elastic bindings 10.
FIG. 7 best exemplifies the configuration of the cavity formed by
the "Z" and reverse "Z" of the vertical double pleat structure. The
vertical double pleat structure provides a place for the wearer's
nose.
In order to effect the proper cooperation between the elements of
the surgical face mask, the wearer should extend the center portion
intermediate the two vertical double pleat structures so as to
explode each of the vertical double pleat structures. This will
expand the "Z" configuration and will generally make the angles in
the "Z" less acute. A box-like structure having a depth "D" and a
length in a horizontal direction approximately equal to 3A is
formed. By "popping out" the frontal portion of the flexible porous
pad 2, each of the folds will provide a semi-rigid support
structure for the box-like configuration. The folds will be rigid
enough to maintain the frontal portion of the flexible porous pad 2
away from the wearer's nose and mouth and yet the fold will not
irritate or otherwise impede the wearer as might occur with rigid
support members.
After the frontal portion of the mask has been "popped out" to form
the box-like structure, the mask is placed over the wearer's nose
and mouth. The foam strip 24 is in contact with the bridge of the
wearer's nose and the lower mask strip 20 is below the lower lip of
the wearer. The lower mask strip 20 is then tied behind the
wearer's head and the flexible strip 12 is deformed to assume the
contours of the bridge of the wearer's nose. The dual wire
structure 14 and 16 in the flexible strip 12 allows the wearer to
fashion the flexible strip 12 into a series of compound curves.
This aids in accommodating individual variation in the bridge
configuration of the wearer. One of the wires 14 may be bent into
one particular configuration while the other one of the wires 16
may be bent into a substantially different configuration.
After the flexible strip 12 has been shaped to follow the contours
of the bridge of the wearer's nose, the upper mask strip 22 is tied
behind the wearer's head. The upper mask strip 22 is placed over
the wearer's ears. The combination of the flexible strip 12 and the
foam strip 24 provides an effective gasket across the bridge of the
wearer's nose and aids in maintaining the flexible porous pad 2
against the wearer's cheekbones. This aids in preventing the
introduction of air-borne bacteria from the patient and minimizes
the possibility of infection from the patient or infection by the
patient from the physician.
Different types of material may be employed for the inner layer 4
of non-woven fiber material, the outer layer 6 of non-woven fiber
material, and the filter mat or cover stock 8. For example, the
inner layer 4 of non-woven fiber material might be a face mask
fiber which is a non-woven fiber material composed of rayon fibers
bonded together with an acrylic type resin adhesive and having an
average weight of approximately 300 grains per square yard. The
tensile strength in the long direction typically might be in the
neighborhood of 17 pounds per four ply thickness of material per 1
inch of width. The tensile strength in the cross direction for the
inner layer of non-woven fiber material might typically be
approximately 1.5 pounds per four ply layer thickness per 1 inch of
width.
The outer layer 6 of non-woven fiber material may be of a different
composition or weight than the inner layer 4 of non-woven fiber
material. For example, fabric which is also primarily composed of
rayon fibers bonded with an acrylic type resin adhesive may be
used. However, the outer fabric may have a weight of 240 grains per
square yard, a tensile strength in the long direction of
approximately 35 pounds per 12 ply thickness of material per one
inch of width, and a tensile strength in the cross direction of
approximately 3.6 pounds per twelve ply thickness of material per 1
inch of width.
The filter mat, or cover stock can be of a variety of materials. An
antiseptic solution may be placed in the cover stock prior to
placing the cover stock into the flexible porous pad 2. One variety
of filter material which may be employed is a web of rayon, natural
fiber abaca, monocrylic fibers, glass fibers, and a binder. The
basic weight of the filter typically might be in the vicinity of
37.9 .+-. 10 percent pounds per five hundred sheets. The thickness
of the filter mat may be in the vicinity of 10 microns and the air
permeability might be on the average of 300 cubic feet of air per
square foot of filter material per minute, plus or minus 10
percent. Quaternary compounds may be used as antiseptics by soaking
the filter mat in the compound prior to assembling the inner layer,
the outer layer and the filter mat into a flexible porous pad.
Amino acid sulphates such as Cytox, manufactured by American
Cyanamid may also be used as antiseptics.
The terms and expressions which have been employed have been used
as terms of description and not of limitation, and there is no
intention in the use of such terms and expressions of excluding any
equivalents of the features shown and described or portions
thereof, but it is recognized that various modifications are
possible within the scope of the invention claimed and particularly
of the specific embodiment disclosed.
* * * * *