Face mask with flap and method of making the same

Abstract

A face mask and method of making it are disclosed. The face mask has a layered construction including an elongated elastic nonwoven sheet having a central portion and first and second lateral end portions on opposite sides of the central portion; a filtering web portion bonded to the central portion of the elastic nonwoven sheet; and a first flap bonded to the central portion of the elastic nonwoven sheet, wherein the first flap is smaller in area than the filtering web portion, and wherein the first flap is bonded along one of the top edge or the bottom edge of the central portion. A dispenser including a plurality of the face masks, a stack of a plurality of the face masks, and a continuous layered web having a plurality of face masks disposed thereon are also disclosed.

1 . A face mask comprising:
 an elastic nonwoven sheet having an elongated shape, a central portion, first and second lateral end portions on opposite sides of the central portion, a first ear opening or perforation in the first lateral end portion, and a second ear opening or perforation in the second lateral end portion;   a filtering web portion bonded to the central portion of the elastic nonwoven sheet, wherein the filter web portion extends from a top edge to a bottom edge of the central portion; and   a first flap bonded to the central portion of the elastic nonwoven sheet, wherein the first flap is smaller in area than the filtering web portion, and wherein the first flap is bonded along one of the top edge or the bottom edge of the central portion.   
     
     
         2 . The face mask of  claim 1 , further comprising a second flap bonded to the central portion of the elastic nonwoven sheet, wherein the second flap is smaller in area than the filtering web portion, and wherein the second flap is bonded along one of the top edge or the bottom edge of the central portion, which is the opposite edge from the first flap. 
     
     
         3 . The face mask of  claim 2 , wherein the first flap and second flap are formed from a common portion of flap material that has lateral side portions connecting the first flap and the second flap, or wherein the first flap and second flap are formed from a common portion of flap material that has a removable perforated section with a shape defining the first flap and the second flap. 
     
     
         4 . The face mask of  claim 1 , wherein the first flap comprises more than one ply. 
     
     
         5 . The face mask of  claim 1 , further comprising a second web portion bonded to the central portion of the elastic nonwoven sheet, wherein the second web portion extends from the top edge to the bottom edge of the central portion. 
     
     
         6 . The face mask of  claim 5 , wherein at least one of the filtering web portion or the second web portion has at least one pleat. 
     
     
         7 . The face mask of  claim 1 , wherein the elastic nonwoven sheet has at least one cut in the central portion. 
     
     
         8 . The face mask of  claim 1 , wherein at least a portion of the first flap not along the top edge or bottom edge is bonded to the central portion of the elastic nonwoven sheet. 
     
     
         9 . A dispenser comprising a container enclosing a plurality of face masks comprising the face mask of  claim 1 , the container having at least one side with an aperture for removing the plurality of face masks. 
     
     
         10 . A stack of interfolded face masks comprising the face mask of  claim 1 . 
     
     
         11 . A method of making a face mask, the method comprising:
 providing an elastic nonwoven web continuous in a machine direction, the elastic nonwoven web having a central lane extending in the machine direction;   layering a filtering web onto the central lane of the elastic nonwoven web to provide a layered web, the filtering web being continuous in the machine direction and having a cross-web width that is narrower than a cross-web width of the elastic nonwoven web;   cutting a web of flap material to provide a flap; and   bonding the elastic nonwoven web, the filtering web, and the cut web of flap material together to provided a bonded, layered web; and   stamping a face mask into the bonded, layered web, the face mask comprising a portion of the elastic nonwoven web, a portion of the filtering web, and a first flap, the portion of the elastic nonwoven web having an elongated shape with a central portion stamped from the central lane of the elastic nonwoven web and first and second lateral end portions on opposite sides of the central portion, wherein the portion of the filtering web extends from a top edge to a bottom edge of the central portion, wherein the first flap is smaller in area than the filtering web portion, and wherein the first flap is bonded along one of the top edge or the bottom edge of the central portion.   
     
     
         12 . The method of  claim 11 , wherein the web of flap material is provided as a continuous web in the machine direction, wherein cutting the web of flap material comprises providing spaced-apart openings in a central portion of the web of flap material while maintaining continuous lateral side portions, wherein the spaced-apart openings define at least the first flap, and wherein bonding the layered web includes bonding the continuous lateral side portions to the filtering web and the elastic nonwoven web. 
     
     
         13 . The method of  claim 11 , wherein the web of flap material is provided as a continuous web in the machine direction, wherein cutting the web of flap material comprises perforating the web of flap material to provide a series of spaced-apart perforated sections in the web, and the first flap is provided after removing the flap material within the perforated section. 
     
     
         14 . The method of  claim 11 , wherein the web of flap material is provided as a continuous web in the machine direction, wherein cutting the web of flap material comprises slitting the web of flap material without removing material from the web, and wherein the slitting provides the first flap and a second flap. 
     
     
         15 . The method of  claim 11 , wherein the flap material web has more than one ply. 
     
     
         16 . A flat, stretchable face mask comprising:
 a layer of elastic material;   a partial layer of a flat-pleated material having at least one flat pleat; and   a flap smaller in area than the partial layer,   
       wherein upon stretching the flat, stretchable face mask, the elastic material stretches and the at least one flat pleat at least partially opens to expand the at least one partial layer, and wherein the flap can be lifted to create a space for a wearer's nose or chin. 
     
     
         17 . The flat, stretchable face mask of  claim 16 , wherein there is at least one cut in the layer of elastic material. 
     
     
         18 . The flat, stretchable face mask of  claim 16 , wherein the flat pleated material has multiple flat pleats. 
     
     
         19 . The flat, stretchable face mask of  claim 16 , wherein the face mask comprises two flaps each smaller in area than the partial layer. 
     
     
         20 . The face mask of  claim 1 , wherein the filtering web portion is bonded to the central portion of the elastic nonwoven sheet in a manner such that the central portion has a reduced elongation in at least one direction relative to the first and second lateral end portions.