PROTECTIVE FACE MASK

Abstract

A protective face mask may comprise an outer housing including a plurality of ventilation holes, and an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes. The protective face mask may also include a replaceable filter configured to be received in a space between the inner housing and the outer housing. In some embodiments, the protective face mask includes a dual chamber breathing design configured to reduce moisture collection within the mask.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/005,302; filed Apr. 4, 2020; entitled FACE MASK; and having an attorney docket number SCALISI.010P.

BACKGROUND

Field

Various embodiments disclosed herein relate to protective face masks. Certain embodiments relate to protective face masks including a dual breathing chamber.

Description of Related Art

Protective face masks can prevent the spread of illness by providing a barrier between the external environment and a mouth and nose of a user. Protective face masks may also filter the air breathed by the user. Protective face masks often cover the lower portion of the user's face and are secured with a strap(s) and/or tie(s). The strap(s) and/or tie(s) may go around a user's head, or may secure around the user's ears. Protective face masks may be worn by healthcare workers, anyone working in an environment with large amounts of particulate matter in the air (e.g., firefighters, construction workers, etc.), and anyone in the general public who desires protection from pollution and/or illness.

SUMMARY

The disclosure includes a protective face mask, and in some embodiments, the protective face mask includes an outer housing including a plurality of ventilation holes, and an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes, wherein a space between the inner housing and the outer housing is configured to receive a replaceable filter. The inner housing may comprise a partition configured to divide the inner housing into an upper chamber and a lower chamber.

In some embodiments, when the mask is coupled to a face of the user, the partition is configured to be located below the nose of the user and above the mouth of the user. The partition may comprise a silicone overmold. In some embodiments, the silicone overmold is further configured to form a seal against a face of the user. The upper chamber may be configured to receive the nose of the user and the lower chamber may be configured to receive the mouth of the user. In some embodiments, the division of the inner housing into the upper chamber and the lower chamber is configured to reduce moisture collection on the replaceable filter.

The outer housing may be configured to receive the inner housing via a friction fit. In some embodiments, the outer housing is configured to receive the inner housing via a channel lock. The outer housing may comprise a female portion of the channel lock that extends around an inner perimeter of the outer housing, and the inner housing may comprise a male portion of the channel lock that extends around an outer perimeter of the inner housing.

In some embodiments, the outer housing and the inner housing comprise a material configured to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties to the protective face mask. The material may comprise silver nanoparticles.

In some embodiments, the outer housing comprises a first aperture located along a first side of the outer housing and a second aperture located along a second side of the outer housing located opposite the first side, wherein the first aperture and second aperture are configured to receive a strap. The strap may comprise a material that is configured to stretch and an adjusting mechanism configured to adjust a length of the strap. In some embodiments, the material includes silver nanoparticles.

The replaceable filter may comprise four layers. In some embodiments, the four layers comprise a first sealed filter, a flux filter, a carbon filter, and a second sealed filter. The outer housing may define a first width and the inner housing may define a second width, wherein the first width is larger than the second width.

In some embodiments, each hole in the first plurality of ventilation holes defines a first area and each hole in the second plurality of ventilation holes defines a second area, wherein the second area is larger than the first area. Each hole in the first plurality of ventilation holes may define a shape that is at least one of substantially round and substantially ovoid. Each hole in the second plurality of ventilation holes may define a shape that is substantially hexagonal.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages are described below with reference to the drawings, which are intended to illustrate, but not to limit, the invention. In the drawings, like reference characters denote corresponding features consistently throughout similar embodiments.

FIG. 1 illustrates a perspective view of a user wearing a face mask, according to some embodiments.

FIG. 2 illustrates a front perspective view of a face mask, according to some embodiments.

FIG. 3 illustrates a back perspective view of a face mask, according to some embodiments.

FIG. 4 illustrates a front view of a face mask, according to some embodiments.

FIG. 5 illustrates a cross-sectional view of a face mask being worn by a user, according to some embodiments.

FIG. 6 illustrates a back view of a face mask, according to some embodiments.

FIG. 7 illustrates a side view of a face mask, according to some embodiments.

FIGS. 8A and 8B illustrate top and bottom views, respectively, of a face mask, according to some embodiments.

FIGS. 9 and 10 illustrate exploded views of a face mask, according to some embodiments.

FIG. 11 illustrates a perspective view of a face mask with a strap, according to some embodiments.

FIG. 12 illustrates layers of a filter of a face mask, according to some embodiments.

FIG. 13 illustrates the relative widths of an inner housing and an outer housing of a face mask, according to some embodiments.

DETAILED DESCRIPTION

Although certain embodiments and examples are disclosed below, inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims appended hereto is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order dependent. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components.

For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.

COMPONENT INDEX

• 10—face mask
• 12—outer housing
• 14—first plurality of ventilation holes
• 16—inner housing
• 18—nose
• 20—mouth
• 22—user
• 24—second plurality of ventilation holes
• 28—replaceable filter
• 30—partition
• 32—upper chamber
• 34—lower chamber
• 36—overmold
• 38—female portion of channel lock
• 40—male portion of channel lock
• 42—inner perimeter (of outer housing)
• 44—outer perimeter (of inner housing)
• 48—aperture
• 50—first side
• 52—second side
• 54—strap
• 56—adjusting mechanism
• 58—layers of filter
• 58a—first sealed filter
• 58b—flux filter
• 58c—carbon filter
• 58d—second sealed filter
• 60—first width
• 62—second width

FIG. 1 shows a user 22 wearing a face mask 10. It should be noted that throughout this disclosure, the terms “face mask”, “mask”, and “protective face mask” may be used interchangeably. The user 22 is shown wearing the face mask 10 such that it covers much of the lower half of the user's face, including the user's nose and mouth. The amount of the user's 22 face covered by the mask 10 may depend on a shape and/or size of the user's 22 face. FIG. 1 also includes a strap 54, which in many embodiments, is used to couple the face mask 10 to the face of the user 22. The strap 54 may be configured to wrap around the head of the user 22, as shown in FIG. 1 and FIG. 11, which will be discussed in greater detail later in the disclosure. In some embodiments, the strap 54 comprises two loop-style straps designed to hook around the ears of the user 22. The strap 54 may be a continuous piece of material or a plurality of individual pieces of material. Additional properties of the strap 54 will be discussed with reference to FIG. 11.

FIG. 2 illustrates a front perspective view of the face mask 10, according to some embodiments. As shown in FIG. 2, the face mask 10 may include an outer housing 12 and an overmold 36. The overmold 36 may be coupled to the outer housing 12 via an inner housing 16, as will be discussed later in this disclosure. In many embodiments, the outer housing 12 includes a first plurality of ventilation holes 14. As illustrated in FIG. 2, each hole in the first plurality of ventilation holes 14 may be substantially ovoid in shape. In some embodiments, each hole is substantially circular. Each hole in the first plurality of ventilation holes 14 may be any suitable shape. Though FIG. 2 shows the face mask 10 including a solid band with no ventilation holes extending across a center portion of the outer housing 12, in some embodiments, substantially an entire surface of the outer housing 12 includes the first plurality of ventilation holes 14.

FIG. 2 also includes an aperture 48. In many embodiments, the aperture 48 is configured to receive at least part of a strap 54 to thereby enable coupling of the face mask 10 to the face of a user 22. FIG. 2 also shows the face mask 10 including an upper curved portion that extends above the main body of the face mask 10. In some embodiments, this upper curved portion is configured to cover the nose of the user 22. This feature may provide a comfortable fit and strong seal against the face of the user 22. In some embodiments, the face mask 10 including the upper curved portion is especially designed for use by healthcare workers or others exposed to germs, pollution, and the like at high volumes. The embodiment of the face mask 10 shown in the figures may be considered a “professional protective face mask” and/or a “commercial protective face mask”. In some embodiments, the face mask 10 does not include the upper curved portion, and instead resembles a more symmetrical curved shape, where a top portion of the mask substantially reflects a bottom portion of the mask. The face mask 10 may be sized to fit a child. In some embodiments, a child-size face mask 10 is configured to fit an average-sized child up to about 10 years old.

FIG. 3 illustrates a back perspective view of the face mask 10, according to some embodiments. As shown, the face mask 10 may include the outer housing 12, shown in FIGS. 1 and 2, as well as an inner housing 16. In many embodiments, the face mask 10 also includes an overmold 36, which in turn includes a partition 30 configured to separate the inner housing 16 into a dual breathing chamber comprising two ventilation channels: an upper chamber 32 and a lower chamber 34. The partition 30 may be configured to sit against an area above the upper lip of the user 22 below the nostrils, such that the upper chamber 32 may be configured to receive the nose of a user 22, and the lower chamber 34 may be configured to receive the mouth of the user 22. In many embodiments, separating the nose and mouth of the user 22 reduces moisture collection in the mask, as inhalation and exhalation occur in separate chambers. In addition, most of the moisture collected in the mask may be concentrated to the chamber receiving exhalation (e.g., the lower chamber 34 when the user 22 is exhaling through their mouth). This may enable the inhalation chamber (e.g., the upper chamber 32 when the user 22 inhales through their nose) to remain completely or nearly completely dry.

Using a dual breathing chamber and reducing moisture collection may provide a more comfortable mask-wearing experience for the user 22. In many embodiments of using a traditional face mask, users are forced to re-inhale air that was recently exhaled. In addition to the general discomfort this may cause (e.g., breathing in warm, moist, potentially odorous air), recently exhaled air is higher in carbon dioxide than “fresh” air, and inhaling carbon dioxide in excessive amounts can be harmful to health. As previously stated, the chamber used for inhalation may remain dry, thus enabling the user 22 to inhale fresh, dry air rather than stale and/or damp air. The dual breathing chamber may also provide other benefits, including but not limited to: faster airflow circulation, less obstruction in breathing, reduced “fogging” of glasses worn by the user 22, a general fresh and/or dry feeling on at least a portion of the user's 22 face covered by the mask 10, and preventing the spread of germs via droplets.

As will be discussed in greater detail with reference to FIG. 12, in some embodiments the face mask 10 includes a replaceable filter. The dual breathing chamber may extend the amount of time that the replaceable filter is effective by reducing the amount of moisture collected on the filter. For example, under heavy use (e.g., in a healthcare setting), the replaceable filter may last about 2 or 3 days. Under everyday use (e.g., a member of the general public wearing a mask for shorter periods of time, such as when running errands), the replaceable filter may last about 5 days.

In many embodiments, the overmold 36 shown in FIG. 3 comprises a piece of silicone overmolded onto the inner housing 16. The silicone may comprise soft fitted silica gel, which may provide a comfortable and flexible fit to the face of the user 22. A flexible fit of the overmold 36 may enable users 22 of varied face shapes and/or sizes to comfortably wear the face mask 10. In some embodiments, the silicone comprises 8 mm silicone. The overmold 36 may be configured to form a seal on the face of the user 22. In some embodiments, the seal contributes to the longevity of the replaceable filter and general effectiveness of the mask 10 by substantially eliminating the entrance of air—including bacteria, viruses, pollutants, and the like—into the mask 10 through any portion other than the first plurality of ventilation holes 14 on the outer housing 12.

FIG. 3 also illustrates the second plurality of ventilation holes 24. As shown, each hole in the second plurality of ventilation holes 24 may define a substantially hexagonal shape. Each hole may also define a substantially octagonal, pentagonal, heptagonal, rectangular, or any other suitable shape. In some embodiments, and as can be seen when comparing FIG. 2 and FIG. 3, each hole in the second plurality of ventilation holes 24 may define a larger area than each hole in the first plurality of ventilation holes 14.

FIG. 4 shows a front view of a face mask 10, according to some embodiments. Similar to FIG. 2, FIG. 4 includes the outer housing 12 and the first plurality of ventilation holes 14. FIG. 4 expands on the aperture 48 shown in FIG. 2 by including both a first aperture 48a and a second aperture 48b. In some embodiments, the first aperture 48a is coupled to a first side 50 of the outer housing 12, and the second aperture 48b is coupled to a second side 52 of the outer housing 12. As previously discussed, the apertures 48a, 48b may be configured to receive a portion of a strap 54 (not shown) in order to enable coupling the mask 10 to the face of a user 22. In some embodiments, each aperture 48a, 48b is configured to receive individual straps configured to loop around the ears of the user 22. FIG. 4 also includes a dashed line extending down substantially the middle of the face mask 10 with a note to see FIG. 5, indicating a cross-sectional view.

FIG. 5 illustrates the cross-sectional view of the face mask 10 located on a user 22, drawn in profile. FIG. 5 shows that, in some embodiments and as discussed with reference to FIG. 3, the partition 30 is located above the mouth 20 and below the nose 18 of the user 22. The partition 30 thereby separates the face mask 10 into an upper chamber 32, shown receiving the nose 18, and a lower chamber 34, shown receiving the mouth 20. It should be noted that though the user 22 is illustrated in FIG. 5 as inhaling through their nose 18 and exhaling through their mouth 20, the inverse is possible and may be practiced while wearing the face mask 10. It should also be noted that the face mask 10 may cover less, more, or substantially the same amount of the face of the user 22 illustrated in FIG. 5. As previously mentioned, in many embodiments, the mask 10 is configured to fit comfortably on a variety of face shapes and sizes, so the portion of a user's 22 face covered by the mask 10 may depend on the user's 22 face shape and/or size.

FIG. 6 shows a back view of the face mask 10, including the outer housing 12, the inner housing 16, and the partition 30. FIG. 6 also illustrates that, in many embodiments, the face mask includes a replaceable filter 28. When the inner housing 16 is coupled to the outer housing 12, the replaceable filter 28 may be located in a space between the inner housing 16 and the outer housing 12. The replaceable filter 28 will be discussed in more detail with reference to FIG. 12. FIG. 6 also includes the first aperture 48a and the second aperture 48b.

FIG. 7 illustrates a side view of the face mask 10, according to some embodiments. As shown, the face mask 10 may have a generally curved shape in order to accommodate the nose 18 and mouth 20 of the user 22 that are received within the mask 10, as shown in FIG. 5. FIG. 7 also shows the first aperture 48a. I should be noted that the first aperture 48a, as well as the second aperture 48b, may comprise a form and/or shape different than what is shown in the Figures. For example, the apertures 48a, 48b may comprise hooks or other such mechanisms designed to retain at least a portion of a strap (or straps) 54. FIGS. 8A and 8B illustrate top and bottom views, respectively, of the face mask 10, according to some embodiments. As also shown in FIG. 7, FIGS. 8A and 8B illustrate the curved nature of the face mask 10. Though not labeled, the mask 10 shown in FIGS. 8A and 8B includes the overmold 36. In some embodiments, the face mask 10 does not include the overmold 36.

FIGS. 9 and 10 show exploded top and front views, respectively, of the face mask 10, according to some embodiments. As shown in FIGS. 9 and 10 and as discussed with reference to the other Figures, the face mask 10 may include an overmold 36, an inner housing 16, a replaceable filter 28, and an outer housing 12. As previously discussed, in some embodiments the overmold 36 comprises a soft silicone molded onto the inner housing 16. The overmold 36 may be configured to be molded to an interior portion, including an inner perimeter, of the inner housing 16. Alternatively, the overmold 36 may be configured to be molded to an exterior portion of the inner housing 16.

In many embodiments, the inner housing 16 and the outer housing 12 comprise an at least semi-rigid material, such as plastic. In some embodiments, the plastic is bisphenol A (“BPA”) free for user safety. The housings 12, 16 may comprise polypropylene (“PP”) plastic. In many embodiments, the housings 12, 16 comprise acrylonitrile butadiene styrene (“ABS”) plastic. Whether comprising PP or ABS plastic, or a combination thereof, in some embodiments the material of the housings 12, 16 includes embedded silver nanoparticles. In many embodiments, the integration of silver nanoparticles into the housings 12, 16 imparts at least one of anti-bacterial, anti-viral, and anti-fungal properties to the face mask 10. In some embodiments, the material composition includes at least 1% silver nanoparticles of the total composition. In some embodiments, the material composition includes less than 1% silver nanoparticles. In some embodiments, the material composition includes less than 0.1% silver nanoparticles. In some embodiments, the material composition includes less than 0.01% silver nanoparticles. In addition, the housings 12, 16 may be able to be washed, such as with warm water and soap, or rinsed, such as with rubbing alcohol, and re-used without breakdown of the housing material. The re-usable nature of the face mask 10 may reduce the amount of waste produced in particular industries, and by the general public, especially when compared to traditional single-use masks. In addition, the face mask 10 may present significantly lower monthly costs than traditional single-use masks.

In some embodiments, the outer housing 12 is configured to detachably receive the inner housing 16 via a friction fit. As previously mentioned, the replaceable filter 28 may be located between the outer housing 12 and the inner housing 16 when the housings are coupled together. In some embodiments, the outer housing 12 is configured to detachably couple to the inner housing 16 via a channel lock. FIG. 9 shows that, according to some embodiments, the inner housing 16 includes a male portion of the channel lock 40 and the outer housing 12 includes a female portion of the channel lock 38. The male portion 40 may be located along an outer perimeter 44 of the inner housing 16, and the female portion 38 may be located along an inner perimeter 42 of the outer housing 12, as illustrated in FIG. 9. As such, the female portion 38 may be configured to receive the male portion 40, thereby detachably coupling the outer perimeter 44 of the inner housing 16 to the inner perimeter 42 of the outer housing 12. FIG. 10 also shows the male portion 40 located along the outer perimeter 44 of the inner housing 16.

FIG. 11 shows another perspective view of the face mask 10, and includes the strap 54 and an adjusting mechanism 56. As previously discussed, different forms of the strap 54 are possible. FIG. 11 illustrates that, in some embodiments, the strap 54 comprises a continuous strap configured to use at least one aperture 48 to form two loops around the back of the head of a user 22. The adjusting mechanism 56 may be used to adjust the fit of the mask 10 by shortening and/or lengthening the strap 54. In some embodiments, the strap 54 comprises a stretchy material. The material may comprise nylon, elastic, another suitable material, or any combination thereof. Similar to the material comprising the inner and outer housings 12, 16, the strap 54 material may include silver nanoparticles to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties onto the strap 54.

FIG. 12 illustrates the layers 58 of the replaceable filter 28. In some embodiments, and as shown in FIG. 12, the layers 58 include four layers comprising a first sealed filter 58a, a flux filter 58b, a carbon filter 58c, and a second sealed filter 58d. The flux filter 58b may comprise a 2.5 micron filter. As previously mentioned, the replaceable filter 28 may be wearable for about 3 days under heavy use and for about 5 days under light, everyday use. Each layer 58 of the filter 28 may comprise a soft material, and as such, the filter 28 may comprise a soft, flexible combination of materials. In some embodiments, the filter 28 is disposable. By embedding at least one layer 58 with silver nanoparticles, the filter 28 may have similar anti-bacterial, anti-viral, and/or anti-fungal properties as compared to the outer and inner housings 12, 16, and the strap 54. In some embodiments, the filter 28 is available in different sizes. For example, a child-size face mask 10 may require a different size replaceable filter 28 than an adult-size face mask 10.

FIG. 13 includes the outer housing 12 and the inner housing 16, and illustrates their respective widths. In some embodiments, a first width 60 of the outer housing 12 is larger than a second width 62 of the inner housing 16. The relative sizes of each of the housings 12, 16 is also shown in FIGS. 9 and 10 and discussed with reference to how the housings 12, 16 detachably couple together; the outer perimeter 44 of the inner housing 16 couples to the inner perimeter 42 of the outer housing 12 via the channel lock.

In some embodiments, the face mask 10 is KN95 certified. The face mask 10 may also be FDA approved and SGS tested. The face mask 10 may also be customizable and available in a variety of colors and/or patterns.

Interpretation

None of the steps described herein is essential or indispensable. Any of the steps can be adjusted or modified. Other or additional steps can be used. Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one embodiment, flowchart, or example in this specification can be combined or used with or instead of any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different embodiment, flowchart, or example. The embodiments and examples provided herein are not intended to be discrete and separate from each other.

The section headings and subheadings provided herein are nonlimiting. The section headings and subheadings do not represent or limit the full scope of the embodiments described in the sections to which the headings and subheadings pertain. For example, a section titled “Topic 1” may include embodiments that do not pertain to Topic 1 and embodiments described in other sections may apply to and be combined with embodiments described within the “Topic 1” section.

Some of the devices, systems, embodiments, and processes use computers. Each of the routines, processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code modules executed by one or more computers, computer processors, or machines configured to execute computer instructions. The code modules may be stored on any type of non-transitory computer-readable storage medium or tangible computer storage device, such as hard drives, solid state memory, flash memory, optical disc, and/or the like. The processes and algorithms may be implemented partially or wholly in application-specific circuitry. The results of the disclosed processes and process steps may be stored, persistently or otherwise, in any type of non-transitory computer storage such as, e.g., volatile or non-volatile storage.

The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure. In addition, certain method, event, state, or process blocks may be omitted in some implementations. The methods, steps, and processes described herein are also not limited to any particular sequence, and the blocks, steps, or states relating thereto can be performed in other sequences that are appropriate. For example, described tasks or events may be performed in an order other than the order specifically disclosed. Multiple steps may be combined in a single block or state. The example tasks or events may be performed in serial, in parallel, or in some other manner. Tasks or events may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently than described. For example, elements may be added to, removed from, or rearranged compared to the disclosed example embodiments.

Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present.

The term “and/or” means that “and” applies to some embodiments and “or” applies to some embodiments. Thus, A, B, and/or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence. A, B, and/or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments can include A, B, and C. The term “and/or” is used to avoid unnecessary redundancy.

The term “substantially” is used to mean “completely”, “nearly completely”, “exactly”, or “nearly exactly”. For example, the disclosure includes “in some embodiments, substantially an entire surface of the outer housing 12 includes the first plurality of ventilation holes 14”. In this context, the term “substantially” indicates that completely/exactly or nearly completely/exactly the entire surface of the outer housing includes the first plurality of ventilation holes.

The term “about” is used to mean “approximately”. For example, the disclosure includes “In some embodiments, a child-size face mask 10 is configured to fit an average-sized child up to about 10 years old.” In this context, the child-size mask is configured to fit a child up to approximately 10 years old. A child between 8 and 12 years old may fall into the range of “about 10 years old” in the context of this disclosure.

While certain example embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions disclosed herein.

Claims

1. A protective face mask, comprising:

an outer housing including a first plurality of ventilation holes, wherein the first plurality of ventilation holes allow for air ingress and egress;

a replaceable filter removably coupled to the outer housing, wherein the replaceable filter is configured to substantially cover each hole of the first plurality of ventilation holes;

an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes defining a first portion and a second portion, and a solid dividing line that extends between the first portion and the second portion, wherein the solid dividing line defines an upper chamber including the first portion of the second plurality of ventilation holes and a lower chamber including the second portion of the second plurality of ventilation holes, wherein the replaceable filter is removably coupled between the outer housing and the inner housing, and wherein each of the first portion of the second plurality of ventilation holes and the second portion of the second plurality of ventilation holes allow for air ingress and egress; and

an overmold removably coupled to the inner housing, whereby the replaceable filter and the inner housing are located between the outer housing and the overmold, the overmold including a partition extending between the first portion of the second plurality of ventilation holes and the second portion of the second plurality of ventilation holes, wherein when the protective face mask is worn by a user, the partition physically contacts the user between the nose and the mouth and extends substantially an entire width of the inner housing of the protective face mask.

2. (canceled)

3. (canceled)

4. The protective face mask of claim 1, wherein the overmold comprises a silicone overmold.

5. The protective face mask of claim 4, wherein the silicone overmold is further configured to form a seal against a face of the user.

6. The protective face mask of claim 1, wherein the upper chamber is configured to receive the nose of the user and the lower chamber is configured to receive the mouth of the user.

7. The protective face mask of claim 6, wherein a division, via the partition, of the inner housing into the upper chamber and the lower chamber is configured to reduce moisture collection on the replaceable filter.

8. The protective face mask of claim 1, wherein the outer housing is configured to receive the inner housing via a friction fit.

9. The protective face mask of claim 1, wherein the outer housing is configured to receive the inner housing via a channel lock.

10. The protective face mask of claim 9, wherein the outer housing comprises a female portion of the channel lock that extends around an inner perimeter of the outer housing and the inner housing comprises a male portion of the channel lock that extends around an outer perimeter of the inner housing.

11. The protective face mask of claim 1, wherein the outer housing and the inner housing comprise a material configured to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties to the protective face mask.

12. The protective face mask of claim 11, wherein the material comprises silver nanoparticles.

13. The protective face mask of claim 1, wherein the outer housing comprises a first aperture located along a first side of the outer housing and a second aperture located along a second side of the outer housing located opposite the first side, wherein the first aperture and the second aperture are configured to receive a strap.

14. The protective face mask of claim 13, wherein the strap comprises a material that is configured to stretch.

15. The protective face mask of claim 14, wherein the material includes silver nanoparticles.

16. The protective face mask of claim 1, wherein the replaceable filter comprises four layers.

17. The protective face mask of claim 16, wherein the four layers comprise a first sealed filter, a flux filter, a carbon filter, and a second sealed filter.

18. The protective face mask of claim 1, wherein the outer housing defines a first width and the inner housing defines a second width, wherein the first width is larger than the second width.

19. The protective face mask of claim 1, wherein each hole in the first plurality of ventilation holes defines a first area and each hole in the second plurality of ventilation holes defines a second area, wherein the second area is larger than the first area.

20. (canceled)

21. (canceled)

22. (canceled)

23. The protective face mask of claim 1, wherein the replaceable filter is arranged and configured to cover an entire surface of the inner housing.

24. The protective face mask of claim 1, wherein the first portion of the second plurality of ventilation holes and the third second portion of the second plurality of ventilation holes are arranged in a honeycomb pattern.

25. The protective face mask of claim 1, wherein the outer housing and the inner housing define substantially the same shape.

26. The protective face mask of claim 7, wherein the user is configured to inhale through the nose via the upper chamber, and exhale through the mouth via the lower chamber.