Face mask with enhanced seal and method

A method for preventing liquids and aerosols from contacting the face of a person wearing a flexible, non-molded surgical style face mask having a plurality of layers of selected materials, comprising the steps of:

• placing each layer of material having a generally rectangular shape and a top edge, a bottom edge, and lateral sides in juxtaposition to form a filter body for the mask;
• pleating the layers of material;
• connecting the layers of material along the top edge, bottom edge and the lateral sides of the generally rectangular shape to form the filter body;
• forming a pair of flexible flaps from material that is different from the selected material used to form the filter body;
• attaching the flaps to respective sides of the filter body;
• providing means for gathering said flaps into sealing contact with a wearer's face, said means for gathering comprising securing means extending through each flap for holding the mask on the face of a wearer for gathering said flexible flap material, and for preventing undesired fluid flow to between the respective sides of the mask body and a wearer's face
• providing an elongated malleable member in the top edge of the mask body for conforming the top edge to the contours of a wearer's nose and cheeks;
• and
• positioning said mask body over the nose and mouth of a wearer such that the bottom edge of the mask body extends under the chin of the wearer, to prevent undesired fluid flow between the top edge, the bottom edge, and a wearer's face.

A surgical style face mask comprising:

• a non-molded flexible filter body having a generally rectangular configuration and multiple pleats sized to fit over the mouth and nose of a wearer, the filter body having top and bottom edges with the top edge arranged to extend across the nose and cheeks of the wearer and the bottom edge arranged to extend under the chin of the wearer;
• an elongated malleable member located in the top edge for conforming the top edge to the contours of a wearer's nose and cheeks;
• a flap attached to each side of the filter body and arranged to extend from the filter body;
• the flaps formed from fluid impervious, resilient material;
• means for gatheriing said flaps into sealing contact with a wearer's face, said means for gathering comprising:
• first securing means and second securing means attached to respective flaps and arranged to extend generally about the head of the wearer, the first and second securing means extending through the respective flaps for urging the top edge and the bottom edge into tight engagement with the face of the wearer to prevent undesired fluid flow between the top edge and the bottom edge and the wearer's face;
• and for gathering the flaps and each respective side of the filter body to prevent undesired fluid flow between the respective sides of the filter body and the face of the wearer.

A surgical style face mask comprising:

• a non-molded flexible filter body formed from multiple layers of material having a generally rectangular configuration and multiple pleats sized to fit over the mouth and nose of a wearer, the filter body having top and bottom edges with the top edge arranged to extend across the nose and cheeks of the wearer and the bottom edge arranged to extend under the chin of the wearer;
• an elongated malleable member located in the top edge for conforming the top edge to the contours of a wearer's nose and cheeks;
• a flap attached to each side of the filter body and arranged to extend from the filter body;
• each flap formed from flexible material different from that of the mask body;
• means for gathering said flaps into sealing contact with a wearer's face, said means for gathering comprising:
• a securing means attached to the respective flaps and arranged to extend generally about the head of the wearer, the securing means extending through the flaps for urging the top edge and the bottom edge into tight engagement with a wearer's face to prevent undesired fluid flow between the top edge and the bottom edge and a wearer's face
• and gathering each flap to prevent undesired fluid flow between the respective sides of the filter body and the face of a wearer.