Facemask and Method of Manufacturing Same

Abstract

The present disclosure is directed to a protective facemask absent of a nose wire that can be used in multiple applications, particularly in the medical field. The facemask includes a body having a top edge and a bottom edge. The top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. Further, the top edge includes a treated zone containing a surface coating. The surface coating contains a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.

What is claimed is: 
     
         1 . A facemask, comprising:
 a body comprising a top edge and a bottom edge, the top and bottom edges cooperating with each other to define a periphery that contacts a wearer's face, the top edge comprising a treated zone containing a surface coating, the surface coating comprising a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.   
     
     
         2 . The facemask of  claim 1 , wherein the non-metal malleable material comprises at least one of a polymeric material or a high molecular weight alcohol. 
     
     
         3 . The facemask of  claim 2 , wherein the polymeric material comprises at least one of cyanoacrylates, lightweight polyester thermoplastics, or silcones. 
     
     
         4 . The facemask of  claim 2 , wherein the high molecular weight alcohols comprise at least one of wax or moldable dough. 
     
     
         5 . The facemask of  claim 1 , wherein the surface coating comprises a thin strip configuration. 
     
     
         6 . The facemask of  claim 5 , wherein the thin-strip configuration comprises a rectangular cross-section. 
     
     
         7 . The facemask of  claim 1 , wherein the body further comprises an upper portion and a lower portion secured together along one or more sides of the facemask, at least one of the sides of the facemask being open, the upper and lower portions of the body comprising complimentary shapes. 
     
     
         8 . The facemask of  claim 7 , wherein the upper and lower portions of the body comprise at least one of complimentary trapezoidal shapes or complimentary rectangular shapes. 
     
     
         9 . The facemask of  claim 1 , wherein the body is constructed of an air-permeable material. 
     
     
         10 . The facemask of  claim 1 , further comprising one or more securing members configured to secure the facemask to the wearer's face. 
     
     
         11 . The facemask of  claim 1 , wherein the upper and lower portions are bonded together via at least one of heat or ultrasonic sealing along three sides. 
     
     
         12 . A method of manufacturing a facemask, the method comprising:
 forming a filter body of the facemask having a top edge and a bottom edge, the top and bottom edges cooperating with each other to define a periphery that contacts a wearer's face; and   applying a surface coating to at least a portion of the top edge, the surface coating comprising a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.   
     
     
         13 . The method of  claim 12 , wherein forming the filter body further comprises:
 providing an upper portion and a lower portion of the filter body;   securing the upper and lower portions of the filter body along one or more sides thereof and leaving at least one of the sides of the facemask open, the open side defining the top and bottom edges.   
     
     
         14 . The method of  claim 12 , wherein the non-metal malleable material comprises at least one of a polymeric material or a high molecular weight alcohol. 
     
     
         15 . The method of  claim 14 , wherein the polymeric material comprises at least one of cyanoacrylates, lightweight polyester thermoplastics, or silcones, and wherein the high molecular weight alcohols comprise at least one of wax or moldable dough. 
     
     
         16 . The method of  claim 12 , further comprising applying the surface coating to at least a portion of the top edge so as to form a thin-strip configuration. 
     
     
         17 . The method of  claim 16 , wherein the thin-strip configuration comprises a rectangular cross-section. 
     
     
         18 . The method of  claim 13 , wherein the upper and lower portions of the body comprising complimentary shapes. 
     
     
         19 . The method of  claim 13 , further comprising securing the upper and lower portions of the filter body along one or more sides thereof via at least one of heat or ultrasonic sealing. 
     
     
         20 . The method of  claim 12 , further comprising attaching one or more securing members to the filter body, the securing members configured to secure the facemask to the wearer's face.