Flat Folding N95 Masks

Abstract

The present invention provides mask capable of enabling the mask to be folded into a flat package before use or unfolded into a three dimensional configuration when placed on the face of the wearer.

What is claimed is: 
     
         1 . A face mask comprising:
 at least one layer forming a body with a top end, a bottom end, a lateral first end, a lateral second end;   at least one upper pleat positioned above a center of the body, at least one lower pleat positioned below the center of the body, each pleat extending laterally between the first end and the second end;   a first press weld at the first end and a second press weld at the second end, wherein the press welds secure the mask on a wearer's face;   at least two spot welds positioned at the first end and the second end, wherein the spot welds secure each pleat to the body of the mask to create a rigid panel when the mask is on a wearer's face;   at least one strap, wherein the at least one strap is welded to each of the first press weld and the second press weld; and   a nose clip positioned near at the top end, wherein the nose clip is configured to bend the mask over the wearer's nose to create a seal above the nasal area.   
     
     
         2 . The face mask of  claim 1 , wherein the nose clip comprises at least one over-mold metal core strip or wire embedded in a plastic strip, configured to bridge the nose gap and provide strength of seal. 
     
     
         3 . The face mask of  claim 1 , wherein the nose clip comprises at least three over-mold metal core strip or wire embedded in a plastic strip, configured to bridge the nose gap and provide strength of seal. 
     
     
         4 . The face mask of  claim 1 , wherein the nose clip is a plastic strip having at least three over-mold metal cores embedded within, and wherein each metal core is arranged in parallel in the plastic strip. 
     
     
         5 . The face mask of  claim 1 , wherein the nose clip has a memory function. 
     
     
         6 . The face mask of  claim 1 , wherein the at least one strap comprises a soft rubber adjuster to allow a tight seal when mask is placed on the face of the wearer. 
     
     
         7 . The face mask of  claim 1 , wherein the at least one strap forms a loop configured to wrap around a wearer's head. 
     
     
         8 . The face mask of  claim 1 , wherein the at least one strap forms a loop configured to wrap around a wearer's ear. 
     
     
         9 . The face mask of  claim 1 , wherein the strap, the nose clip and the adjuster combine to create a tight seal on the wearer's face. 
     
     
         10 . The face mask of  claim 1 , wherein the at least one layer comprises an outer layer and an inner layer. 
     
     
         11 . The face mask of  claim 10 , wherein the at least one layer further comprises at least one middle layer positioned between the outer layer and the inner layer. 
     
     
         12 . The face mask of  claim 11 , wherein an outer perimeter of the outer layer, at least one middle layer and the inner layer are welded together. 
     
     
         13 . The face mask of  claim 1 , wherein the mask further comprises a horizontal flat pleat free area created between the at least one upper pleat and the at least one lower pleat in the center of the body configured to form an air chamber. 
     
     
         14 . The face mask of  claim 13 , wherein the horizontal flat pleat free area lands across a center line between the bottom of the wearer's nose and top of the wearer's mouth. 
     
     
         15 . The face mask of  claim 1 , wherein the mask is fully sealed to the wearer's face, when the first press weld and the second press weld end are pulled to tighten by the at least one strap. 
     
     
         16 . A face mask comprising: an outer layer; one or more middle layer; and an inner layer; wherein each layer comprises a body having a substantially oval shape with a top end, a bottom end, a first end, a second end, and comprises at least one upper pleat positioned laterally above a center of the body, at least one lower pleat positioned laterally below the center of the body, wherein a horizontal flat plea-free area is created between the at least one upper pleat and the at least one lower pleat in the center of the body configured to form an air chamber; a first press weld at the first end and a second press weld at the second end, wherein both welded ends are rigid and configured to prevent the first end and the second end of the mask from being deformed when the mask is pulled and placed on a wearer's cheeks;
 at least two spot welds positioned at the first end and the second end, wherein the spot welds secure each pleat to the body of the mask to create a rigid panel when the mask is on a wearer's face;   at least one strap, wherein the at least one strap is welded to each of the first press weld and the second press weld; wherein at least one strap comprises an adjuster to allow a tight seal when mask is placed on the face of the wearer; and   a nose clip positioned near at the top end, wherein the nose clip is configured to bend the mask over the wearer's nose to create a seal above the nasal area; and   wherein the body of the mask is fully sealed to the wearer's face, when the first press weld and the second press end are pulled to tighten by the at least one strap; and   wherein an outer perimeter of the outer layer, one or more middle layer and inner layer are welded together.