Respirator with stretch-panels

Abstract

A disposable respirator made from a filter body having at least one stretch-panel incorporated therein. The stretch-panel allows the respirator to better conform to the wearer's face during movement due to talking, coughing, or general head or neck movement. There may be one or more stretch-panels located underneath the chin or over the cheeks of the wearer.

1 . A disposable respirator which defines an area surrounded by a periphery, the disposable respirator extending across a wearer's nose bridge, across each of the wearer's cheeks, and underneath the wearer's chin for covering the nose and mouth of the wearer, the disposable respirator comprising:
 a filter body comprising a non-elastic material defining a body outer surface area; and   a first stretch-panel comprising an elastic material and having an outer edge defining a portion of the mask periphery, the first stretch-panel defining a panel outer surface area,   wherein the panel outer surface area is less than the filter outer surface area.   
   
   
       2 . The disposable respirator of  claim 1  wherein the first stretch-panel comprises a stretch direction that is about parallel with the outer edge of the first stretch-panel. 
   
   
       3 . The disposable respirator of  claim 1  wherein the first stretch-panel is substantially triangular in shape. 
   
   
       4 . The disposable respirator of  claim 1  wherein the first stretch-panel is air impermeable. 
   
   
       5 . The disposable respirator of  claim 1  wherein the first stretch-panel is attached to the filter body with a thermal bond. 
   
   
       6 . The disposable respirator of  claim 1  further comprising a head strap, wherein the head strap is connected to the filter body. 
   
   
       7 . The disposable respirator of  claim 1  further comprising a second stretch-panel, wherein the first stretch-panel and the second stretch-panel are attached to the filter body, and wherein the panel outer surface area is defined by the outer surface area of the first stretch-panel and the outer surface area of the second stretch-panel. 
   
   
       8 . The disposable respirator of  claim 7  wherein the first and the second stretch-panels are substantially triangular in shape. 
   
   
       9 . The disposable respirator of  claim 7  wherein the first and the second stretch-panels comprise four-sided polygons. 
   
   
       10 . The disposable respirator of  claim 7  wherein the first stretch-panel and the second stretch-panel are spaced apart and arranged to fit over each of the wearer's cheeks. 
   
   
       11 . The disposable respirator of  claim 7  wherein the first stretch-panel and the second stretch-panel are connected together. 
   
   
       12 . The disposable respirator of  claim 1  further comprising an exhalation vent located on the filter body or the first stretch-panel. 
   
   
       13 . The disposable respirator of  claim 1  wherein the filter body comprises a sheet-like blank that is symmetric about a fold line. 
   
   
       14 . The disposable respirator of  claim 13  wherein the first stretch-panel comprises a fold line such that when the respirator is in a flat configuration, the stretch-panel is folded inward toward a body-facing surface of the respirator. 
   
   
       15 . The disposable respirator of  claim 13  wherein the first stretch-panel is symmetrically disposed on the mask with respect to the fold line. 
   
   
       16 . The disposable respirator of  claim 15  wherein the connection between the filter body and the first stretch-panel is air impermeable. 
   
   
       17 . The disposable respirator of  claim 1  wherein the first stretch-panel comprises an elastic film. 
   
   
       18 . The disposable respirator of  claim 17  wherein the first stretch-panel comprises a stretch bonded laminate. 
   
   
       19 . A disposable respirator for a wearer, the respirator comprising:
 a filter body sized to fit over the mouth and nose of the wearer, the filter body having a top edge arranged to extend across the nose and cheeks of the wearer, a bottom edge arranged to extend along a wearer's jaw line, and a seam edge arranged to extend between the wearer's nose to the wearer's chin; and   a triangular stretch-panel attached to the bottom edge of the filter body, wherein the stretch-panel is arranged to fit underneath the wearer's chin.   
   
   
       20 . A disposable respirator for a wearer, the respirator comprising:
 a filter body sized to fit over the mouth and nose of the wearer, the filter body having a top edge arranged to extend across a nose and upper cheeks of the wearer, and a bottom edge arranged to extend along lower cheeks and underneath a chin of the wearer, wherein the bottom edge has two spaced apart notched portions; and a seam edge arranged to extend between the wearer's nose to the wearer's chin; and   a stretch-panel disposed within each of the of notched portions and attached to the filter body.