Technical Field

The present invention relates to a filter in flexible structure providing microbial protection at a high rate up to 99.99 % for use at mainly, health sector, industrial production plants, food sector, close offices, social areas, school, mining quarries, reducing breathing resistance without need for valve use, providing double way protection, and a mask embodiment convenient for use thereof.

Present State of the Art

Masks convenient for use at health sector can be examined in two different categories in respect to use purposes. One of them is dust mask and other one is medical mask. Dust masks are classified as masks subjected to testing by NaCI and paraffin. Masks displaying performance of retaining at 80 % are designated as FFP1 (N80) while those with 95 % as FFP2(N95) and those of 99 % as FFP3(N99). In terms of structure HEPA filters are nonwoven and melt-blown and such structures have low air permeability as they have high difference pressure values.

In order to comfort exhaling - inhaling because of high air resistance, valve structure is used in dust masks and thus CO2 toxicity is prevented. In such case one-way protection (inhaling direction) is provided. Fan structure is employed in some industrial masks in order to overcame HEPA filter resistance. An ambience eligible for microbial load production occurs due to humidity retaining structure of filter and causes considerably serious risk in terms of human health. In addition, because of serious barrier occurring during speaking, voice is not clear enough and thus problems in dual communication occur.

Industrial dust masks are classified as FFP1-FFP2-FFP3 under EN 149 standards. Dust masks have replaceable HEPA filter cartridge in industrial silicone form. Because of having high resistance of breathing, all have valve structure. Such structures are interconnected with a structure similar to filter cartridge screwing system. Single filter cartridge or dual filter cartridges are used. In other words, they consist of two independent parts. In dual uses, they are generally placed in angular way, on right and left, while in single filter cartridge, located in front side so nose and face are exposed to considerably high pressure and problems such as skin irritation and permanent stains occur in case of long time uses. In addition, since such masks are designed for work areas, mining and heavy industrial ambiences, they are not eligible for daily uses.

Since valve systems are parts similar to membrane structures closing when inhaled and opening outward when exhaling, it may fail to or lose its function due to humidity occurring after breathing and humidity entering in together exhaled air. Valve masks provide one-way protection. They can not provide two-way protection.

Although one use dust masks have structures with and without valve, N99 masks do not have model without valve. Since filter structures are similar, air resistance is considerably high and effective use duration is maximum up to 3 hours. Single use mask of both EN 149 and EN 14683 are mask 3 M 1860 model. This model is of N95 standard and Type II level. When such mask type is used, since breathing resistance increases too much, oxygen level of blood reduces up to 60 % and symptoms such as headache, tiredness, distraction etc. occur. In addition, due to valve structure, one way protection is provided and risk for those near user continues.

For instance, patent document numbered TR2020/06926 discloses a mask forming a closed area between face and outside ambience by protecting face against external factors in the mouth and nose area. Said mask comprises an upper cover located onto the filter preventing mixture of air in external ambience with the air in the internal ambience and valve embodiment provided on the cover, It describes that one way air flow is provided by help of the embodiment.

On the other hand, medical masks also known as surgery masks are tested by micro organisms such as bacteria according to EN 14683 standards. Masks displaying 95 % retaining performance are classified as Type I, those displaying 98 % retaining performance as Type II and those displaying over 98 % retaining performance are classified as Type HR. It comprises nonwoven and melt-blown filter structure. They are single use and do not have types allowing replaceable use. Furthermore as they do not comprise valve structure and do not fit fully onto face and remain open on sides, they can not provide full sealing and protection. Duration of use is 3 hours. For instance, patent document numbered CN111560711 A discloses a single use surgery mask comprising nonwoven filter structure. Said nonwoven structure is made from Polybutylene terephthalate (PBT).

Patent document numbered US2018243674A1 relating to development of HEPA filters in the related field suggests use of materials providing electrostatic polarization in the filter and thus aims to provide capability of longer effective filtering for longer periods. In addition, it discloses that said filter may also comprise two or more different fibre layers.

When dust masks and medical masks available in the related art are examined, it is seen that they have been developed in different structures for different purposes. This limits areas wherein the masks function and also brings various disadvantages. For instance, while valve structure in dust masks provides only one way protection, medical masks do not display more than one use and also provide short term protection.

Since dust masks are only subjected to 0.30 micron and bigger size NaCI and paraffin oil penetration tests, having use area in industrial environments, when they are used in pandemics such as corona virus of 0.12 micron size, their effectiveness is not known. In addition, while their valve structure provides one way protection, they may cause spread of micro-organisms. When not used for long durations, due to high resistance they may reduce oxygen rate in blood and cause weakness, tiredness symptoms. Medical masks are subjected to micro-organism tests but fail to provide full protection due to side leaking problems. The filter systems used therein are similar in both structures and have short use duration.

HEPA filters developed technically and providing long term filtration fail to provide flexible use due do their cartridge structure.

In light of the information given above the related field still needs mask embodiments providing flexible use, capable to take form of surface where they are worn thanks to flexible structure, providing double way protection against any bacteria, virus and dust particulates, increasing oxygen level of blood, having broad use area and having filters eligible for more than one use and proving leakage proof by use of such filters.

Brief Description of the Invention The present invention relates to a mask embodiment having a flexible structure and convenient for use thereof meeting the needs mentioned above, eliminating all disadvantages and providing some additional advantages.

Primary purpose of the invention is to provide a filter of flexible structure which reduces air resistance without the need for use optional valve structure, thus not only making breathing easy but also providing double way protection for both user and people near him/her.

Another purpose of the invention is to provide a filter capable to take shape of user’s face when wearing it alone thanks to its flexible structure.

A further purpose of the invention is to provide a filter convenient for use as both dust mask (N99) and medical mask Type HR wherein effective filtration is provided at air passage each time by making filter layers non-corrugated form of filter layers kwon as UGMA (ultra high efficient gel microbial air filter) in the related art.

A further purpose of the invention is to provide a mask embodiment comprising gel air filter for ultra high efficient dual way microbial protection, valve that is appropriate for optional use.

A further purpose of the invention is to provide a mask embodiment convenient for long duration use (up to 60 hours) not allowing microbial load reproduction and thus not requiring replacement thanks to its hydrophobic structure.

Another purpose of the invention is to provide a mask embodiment not needing use of valve which is found optionally in the mask and cock when used together with filter of the invention.

A further purpose of the invention is to provide a mask embodiment allowing filter replacement.

Another purpose of the invention is to provide a mask embodiment providing creation of a space between mouth and mask and thus preventing contact of filter onto mouth and nose area and thus eliminating allergic reactions. Another purpose of the invention is to provide a mask embodiment comprising magnet system for providing mask cover seat onto body and compressing filter sides by pressing.

Another purpose of the invention is to provide a mask embodiment transmitting sound waves at maximum level by help of high air permeability and contributing improvement of mutual communication.

Another purpose of the invention is to provide a mask embodiment providing high clean air permeability as well as zero filtered air leakage and thus providing high leakage proof.

In order to achieve above mentioned purposes, the invention is a filter reducing air resistance occurring as a result of friction force and providing easy to breath and also providing two way protection for both user and people around him/her and comprises at least a cellular layer having a matrix in the structure permitting flexibility to take shape of surface it covers while compressing and filtering micro-organism and particulates on nano-porosity bio-film texture by means of central acceleration created by centrifuge effect while allowing easy passage of air.

In order to achieve above mentioned purposes the invention is invention is rigid mask embodiment (1) convenient for non-corrugated use of filter (3) reducing resistance of air passing there through subject to friction force with its valve structure that can be opened and closed optionally in any of applications also described above, and in the most basic form comprises

- at least a body (2) having a form compatible with human face structure to cover mouth and nose of user,

- at least a cover (4) allowing replacement of filter (3) thanks to its structure of insertremove onto/from body (2) and providing compressing filter (3) between body (2) and cover (4) and thus providing placement thereof,

- at least a connection member (6) preventing movement of mask embodiment (1) on user’s face by wrapping user's head,

- at least a sealing frame (5) of a flexible structure surrounding sides of body (2) directly contacting user’s face and providing fitting of body (2) onto user’s face,

- at least two magnets (7) one located on body (2) and one on cover (4) providing fixing filter (3) between body (2) and cover (4), - at least a magnet cover housing (8) where at least one of magnet (7) pairs is laced onto cover (4),

- at least a magnet body housing (9) where at least one of magnet (7) pairs is laced onto body (2) and

- Air channels (11) located onto cover (4) and providing air inlet-outlet.

- Optional valve sructure that is located on the air channels (11) positioned on the cover (4) and provides air inlet-outlet, provides humidification and pressure reduction in areas where human population is low.

- Valve opening/closing cover (13) that enables the valve structure to open and close the air channels, valve housing (15) on which the valve cover is locate and valve pin (14) that allows the valve opening/closing cover (13) to fit into the valve socket (15)

The structural and characteristic features and all advantages of the invention will be understood better in the figures given below and the detailed description by reference to the figures. Therefore, the assessment should be made based on the figures and taking into account the detailed descriptions.

Brief Description of the Drawings

Figure 1 is a perspective cross-section view of an application of the filter of the invention.

Figure 2 is a front and rear view of an application of a mask embodiment wherein filter of the invention is used.

Figure 3 is an exploded perspective view of an application of a mask embodiment wherein filter of the invention is used.

Figure 4 is a perspective view of size rates of dust particulates on filter of the invention.

Figure 5 is a perspective view of a channelled structure of a mask embodiment wherein filter of the invention is used.

Figure 6 is a perspective view of a channelled structure of a mask embodiment wherein filter of the invention is used, and size rates of dust particulates thereof. Figure 7 is a retaining-pressure comparison in terms of filter types.

Description of References

1 . Mask embodiment

2. Body

3. Filter

31. Cellular layer

32. Protective layer

4. Cover

5. Sealing frame

6. Connector

7. Magnet

8. Magnet cover housing

9. Magnet body housing

10. Cover interlocking housing

11 . Air channels

12. Body wall

13. Valve opening/closing cover

14. Valve pin

15. Valve housing

Detailed Description of the Invention

In this detailed description, preferred applications of a filter of flexible structure and a mask embodiment convenient for use being subject of this invention are disclosed for the purpose of better understanding of the invention without causing any restrictive effect.

The invention is a filter (3) reducing air resistance occurring as a result of friction force and providing easy to breath and also providing two way protection both for user and people around the user and comprises at least one cellular layer (31) having a matrix allowing passing of air after centrifuging in a nano-porosity gel film texture and flexibility to take shape of surface where it covers. Gel forming film by absorbing into nano and micro size porosities in cellular layer (31) structure is preferably microbial gel and forms a bio-film layer inside porosities. Because microbial material and particulates on small channel surfaces are more in comparison to gases in the air during air enter and exit, they are collected onto curve surfaces due to central acceleration and create pressure. The agents heavier than air are absorbed inside from cellular walls of nano and micro size porosities and are retained there. Thus microorganisms and odours received by user from outside or transmitted to outside ambience by user can be filtered at a rate up to 99.99 % and two-way protection for a period up to 60 hours is provided. Also thanks to high air permeability, sound waves are transmitted at maximum level and problems in mutual communication is prevented.

In an application of the invention said cellular layer (31) preferably has 6-24 mm thickness.

According to an application of the invention, said cellular layer (31) is of sponge structure having nano-porosities of 15-30ppi range.

In a preferred embodiment of the invention, cellular layer (31) is made from organic material.

In a preferred application of the invention said filter (3) comprises at least one protective layer (32) of hydrophobic and flexible structure not allowing dust passage.

Said protective layer (32) is preferably made from nonwoven material.

According to an application of the invention, filter (3) of the invention comprises two protective layers (32) one under and other one on the cellular layer (31). Thus cellular layer (31 ) protection against external effects such as dust is provided. Another advantage of protective layers (32) is that they provide longer retaining period of entering and exiting air on cellular layer (31) and thus increase filtering performance.

In a preferred application of the invention said protective layers (32) are sewed onto cellular layer (31) by means of applying ultrasonic welding process. This is another factor increasing filtering performance. In addition, in order to prevent contact of filter (3) to mouth and nose, a configured filter (3) to provide a convex shape will provide positive contribution for user's inhaling and exhaling. The filter (3) of the invention is convenient for both flexible and rigid mask embodiments without corrugation. Non-corrugation use convenience reduces air pressure and thus provides easy breathing.

Filter of the invention contrary to increase of filtering sensitivity provided by method of lowering sieve range at conventional air filters, provides reduction in pressure loss by means of retaining biofilm material at nano porosities covering curved channels by help of high momentum of micro-organism and particulates of higher intensities by 500-2000 folds while passing of low density gases through broad air channels through lower resistance in mm size on sponge-like matrix.

When used in flexible mask cases, it covers user's face upon taking shape of his/her face thanks to its flexible structure. When used in rigid mask embodiments, it takes shape of filter housing form wherein pressed.

The invention is rigid mask embodiment (1 ) convenient for non-corrugated use of filter (3) reducing resistance of air passing there through subject to friction force with its valve structure that can be opened and closed optionally in any of applications also described above, and in the most basic form comprises

- at least a body (2) having a form compatible with human face structure to cover mouth and nose of user,

- at least a cover (4) allowing replacement of filter (3) thanks to its structure of insertremove onto/from body (2) and providing compressing filter (3) between body (2) and cover (4) and thus providing placement thereof,

- at least a connection member (6) preventing movement of mask embodiment (1) on user’s face by wrapping user's head,

- at least a sealing frame (5) of a flexible structure surrounding sides of body (2) directly contacting user’s face and providing fitting of body (2) onto user’s face,

- at least two magnets (7) one located on body (2) and one on cover (4) providing fixing filter (3) between body (2) and cover (4),

- at least a magnet cover housing (8) where at least one of magnet (7) pairs is laced onto cover (4),

- at least a magnet body housing (9) where at least one of magnet (7) pairs is laced onto body (2) and - Air channels (11) located onto cover (4) and providing air inlet-outlet.

- Optional valve sructure that is located on the air channels (11) positioned on the cover (4) and provides air inlet-outlet, provides humidification and pressure reduction in areas where human population is low.

- Valve opening/closing cover (13) that enables the valve structure to open and close the air channels, valve housing (15) on which the valve cover is locate and valve pin (14) that allows the valve opening/closing cover (13) to fit into the valve socket (15)

The mask embodiment (1) of the invention are used in a broad use area covering mainly health sector, work environments, industrial and daily uses. Filter (3) is replaced only once every 7 days on average and it allows use of other parts other than the filter (3) for long time periods.

In a preferred application of the invention mask embodiment (1) comprises at least a cover interlocking housing (10) providing leakage proof between cover (4) and body (2) located onto cover (4) and also supporting centring of filter (3) between the cover (4) and the body (2), and at least a body wall (12) located on the body (2) and providing compression of filter (3) into cover (4) in coordination with cover interlocking housing (10).

Sealing frame (5) of the body (2) fully seating onto user’s face and thus providing leakage proof of air from sides of the body (2) is preferably made from silicone. Said sealing frame (5) is formed by modelling used as form for human face in order to provide compatibility to human face. Therefore, gel and plaster material are used firstly for copying human face to create face mould. Then sludge model that can be shaped later is provided and transmitted to computer by scanning process and sealing frame (5) embodiment is reproduced by means of 3D modelling. Sealing frame (5) enables reach of only air passing through filter to user and breath from user is discharged outside after passing through filter.

In a preferred embodiment of the invention, air channels (10) located on cover (4) are in grid structure. The air channels (10) provides easy to breath by user and also reduces resistance level. Bair cover (4) can be fitted onto and removed from body (2) by help of magnets (7), magnet cover housing (8) and magnet body housing (9) and allows replacement of filter (5). Thus mask embodiment (1 ) of the invention can be used for years only by replacing the filter (5). A preferred embodiment of the invention comprises at least three magnets (7) pairs, at least three magnet cover housings (8) and at least three magnet body housings (9).

In a preferred embodiment of the invention, in the optional valve structure on the body (2), there is a valve opening/closing cover (13) that activates the valve and opens theair channel when it is turned to the right and a valve housing (15) where the valve opening/xlosing cover is located. Thus, the inventive mask structure provides usage opportunity according to the human population and field of use. In a preferred embodiment of the invention, in the optional valve structure, there is a valve pin (14) that allows the valve opening/closing cover (13) to be fitted into the valve housing (15).

Cover (4), body (2) and sealing frame (5) are in whole while mask of invention is in use and are separated when not in use and thus is in accessory form enabling replacement of filter (3). Therefore, it is possible to use masks without the need for use of the valve continuously in the mask configuration having an optional valve structure.

Thanks to filter (3) being fully hydrophobic and non-corrugated, bio-load reproduction thereon is prevented and risks of occurring during long term use is eliminated. Being gel content provides filtering and prevents two-way passing of clean air without need for valve use. Thus air resistance is kept low and breathing of user is adjusted to keep oxygen level in blood stable.

Porosity diameter of cellular layer (31) (15-30ppi) provides synergic effect also by help of air channels (11 ) located in body (2) and cover (4) and is configured to enable easy air passage. Also air resistance is kept under 6 Pa and thus mask embodiment (1) of the invention enables keeping oxygen level in blood of user at about 97 %.

In a preferred embodiment of the invention, cover interlocking housing (10) comprises clamp structure fully surrounding surface of cover (4) facing body (2) in order to ensure seating of filter (3) onto preferably concave structure cover (4) and prevention of sliding. Thanks to the clamp structure, the filter (3) ultrasonic welded edges are compressed into the clamp structure and thus provide contribution to sealing.

In a preferred embodiment of the invention said connection member (6) is in form of yarn, plastic or strip. In an application of the invention, cover (4) and/or body (2) has channels through which connection member (6) passes. Connection member (6) passes behind head of user and does not make pressure onto ears and thus provides homogenous pressure onto face of user.

With continually replacement of expiring filters (3), the mask embodiment (1) of the invention allows more than one use thereof. Above described applications of mast embodiment (1) of the invention suggest a hybrid product convenient for use as both dust mask and medical mask displaying performance at N99 and Type HR level. One of the biggest advantage of the invention is the lower air resistance provided thereby in comparison to filter and rigid masks used in the related art. In addition, much lighter products are disclosed thanks to use of flexible sponge structure filter (3) applications in rigid mask instead of filters available in the related art and based on cartridge system.