Respirator mask

Abstract

The present application describes a respirator mask (100), the respirator mask (100) comprising a mouth-nose body portion defining an upper edge region (108), the upper edge region (108) comprising a first peak segment (128) and a second peak segment (130), the first peak section (128) and the second peak section (130) can be attached to and make contact with a first front inner side cheek area and a second front inner side cheek area of the face of a wearer when the mask is worn, and the first peak section (128) and the second peak section (130) are located on the first side and the second side of the centrally-arranged groove section (126) respectively. The groove section can be attached to and make contact with the nose of a wearer when the mask is worn.

Description

[0001] This invention relates to a respirator mask, and particularly, but not exclusively, to a maintenance-free respirator mask.

[0002] A standard maintenance-free respirator mask, often referred to as a filtering mask, typically comprises two or more panels of air-filtering material and is worn over the wearer's mouth and nose to prevent potentially harmful particles from entering the wearer's respiratory tract and to protect others from exposure to pathogens exhaled by the wearer. When not in use, the mask usually folds along at least one horizontal or vertical fold line, depending on the number of panels included. This type of mask should be worn comfortably and fit snugly against the wearer's face to minimize air leakage between the mask and the wearer's face. Some maintenance-free respirator masks are designed to fit snugly against the wearer's cheeks and chin; however, the areas below each eye and above the nose are more complex and may have leakage gaps through which contaminants can pass. Furthermore, if the wearer wears eyewear, such as protective glasses or goggles, these glasses may fog up as warm exhaled air is guided upwards from the inside of the mask and condenses on the inside of the glasses through leakage gaps. Additionally, such glasses may bump against the mask and may not rest properly and comfortably on the wearer's face. Conventional maintenance-free respirator masks can also obstruct the wearer's vision, which can be particularly undesirable and frustrating, such as in medical settings.

[0003] The purpose of certain embodiments of the present invention is to provide a maintenance-free respirator mask that fits snugly to the wearer’s face, particularly around the nose and cheek areas, to prevent or at least minimize leakage gaps.

[0004] The purpose of certain embodiments of the present invention is to provide a maintenance-free respirator mask that allows the mask wearer to wear glasses properly and comfortably.

[0005] The purpose of certain embodiments of the present invention is to provide a maintenance-free respirator mask that does not impair the wearer's vision.

[0006] According to a first aspect of the present invention, a respirator mask is provided, comprising: The main body of the mouth and nose defines an upper edge region, which includes a first peak segment and a second peak segment. When the mask is worn, the first peak segment and the second peak segment can respectively fit and contact the first and second anterior inner cheek regions of the wearer's face. The first peak segment and the second peak segment are respectively located on the first and second sides of a centrally located groove segment. When the mask is worn, the groove segment can fit and contact the wearer's nose.

[0007] Optionally, the first peak segment, the second peak segment, and the groove segment define at least five inflection points along the upper edge region.

[0008] Optionally, the upper edge region defines at least seven inflection points along it.

[0009] Optionally, the groove segment is generally concave.

[0010] Optionally, the depth of the groove segment along the central vertical plane from the base of the groove segment to the horizontal tangent connecting the first peak segment and the second peak segment is approximately 4 mm to 10 mm.

[0011] Optionally, the depth of the groove segment is approximately 5 mm.

[0012] Optionally, the base of the groove segment extends equally from the central vertical plane in opposite directions for about 10 mm to 15 mm.

[0013] Optionally, the first peak segment and the second peak segment define a pitch spacing of approximately 45 mm to 75 mm.

[0014] Optionally, the spacing is approximately 55mm to 65mm.

[0015] Optionally, the mouth and nose body portion includes a filter material for capturing potentially harmful gas or vapor particles in response to the wearer's inhalation or exhalation.

[0016] Optionally, the mouth and nose body portion can be folded flat when the mask is removed, and the mouth and nose body portion includes a plurality of connected panels, the plurality of connected panels including an upper panel that defines the upper edge region when the mask is worn.

[0017] Optionally, the plurality of panels includes a lower panel that is positioned below the wearer's chin when the mask is worn, and is connected to the upper panel via a middle panel that is positioned in front of the wearer's mouth when the mask is worn.

[0018] Optionally, when the main body of the mouth and nose is folded flat, the lower panel is located between the middle panel and the upper panel.

[0019] Optionally, the intermediate panel includes an upper edge region, the upper panel is attached along the upper edge region of the upper panel, and the upper edge region of the upper panel includes a peak segment centrally disposed between a first side edge segment and a second side edge segment of the upper edge region, the first side edge segment and the second side edge segment sloping away from the corresponding side of the centrally disposed peak segment in opposite directions toward the corresponding end region of the intermediate panel.

[0020] Optionally, the upper edge region of the middle panel defines at least six inflection points along it.

[0021] Optionally, the centrally located peak of the middle panel has a width of approximately 40 mm to 60 mm.

[0022] Optionally, the centrally located peak of the middle panel is convex and has a radius of curvature of about 200 mm to 220 mm.

[0023] Optionally, each of the first side edge segment and the second side edge segment is concave.

[0024] Optionally, each of the first side edge segment and the second side edge segment is connected to the centrally located peak segment via a corresponding transition segment, each of the transition segments comprising a concave transition segment with a radius of curvature smaller than that of the first side edge segment and the second side edge segment.

[0025] Optionally, the radius of curvature of each concave transition segment is approximately 20 mm to 35 mm.

[0026] Optionally, the middle panel includes a lower edge region along which the lower panel is attached, and the contour of the lower edge region differs from that of the upper edge region of the middle panel, such that the middle panel is asymmetrical about a horizontal axis.

[0027] Optionally, the lower panel includes a lower edge region, and the lower edge region of the lower panel includes a centrally located recessed section, which can fit and contact the wearer's throat area when the mask is worn.

[0028] Optionally, the centrally located recessed section of the lower edge region is located between a first convex section and a second convex section extending toward the corresponding end region of the lower panel.

[0029] Optionally, the respirator mask includes at least one harness strap for securing the mask to the wearer's head.

[0030] Optionally, the respirator mask includes at least one exhalation valve.

[0031] According to a second aspect of the present invention, a respirator mask is provided, comprising: The mouth and nose body portion includes a plurality of connected panels configured to allow the mask to be folded flat when removed, wherein the plurality of connected panels include: an upper panel defining an upper edge region that conforms to and contacts the wearer's face when the mask is worn; a lower panel positioned below the wearer's chin when the mask is worn; and a middle panel positioned in front of the wearer's mouth when the mask is worn.

[0032] The middle panel includes an upper edge region, the upper panel is attached along the upper edge region, and the upper edge region includes a peak segment centrally disposed between a first side edge segment and a second side edge segment of the upper edge region, the first side edge segment and the second side edge segment sloping away from the corresponding side of the centrally disposed peak segment toward the corresponding end region of the middle panel in opposite directions.

[0033] According to a third aspect of the present invention, a respirator mask is provided, comprising: The mouth and nose body portion includes a plurality of connected panels configured to allow the mask to be folded flat when removed, wherein the plurality of connected panels include: an upper panel defining an upper edge region that conforms to and contacts the wearer's face when the mask is worn; a lower panel positioned below the wearer's chin when the mask is worn; and a middle panel positioned in front of the wearer's mouth when the mask is worn.

[0034] The upper panel includes an array of longitudinally extending and laterally spaced reinforcing elements or regions, which are generally centered on the upper panel and located between the upper edge region of the upper panel and the upper edge region of the middle panel.

[0035] Optionally, each reinforcing element or region includes a weld line forming a rib. Attached Figure Description

[0036] Some embodiments of the invention will now be described with reference to the accompanying drawings, in which: Figure 1 A perspective view of a respirator mask in an open and deployed state according to certain embodiments of the present invention is shown; Figure 2 It shows Figure 1 A plan view of the face mask; Figure 3a A rear view of the mask body is shown without the straps and when it is in a closed and folded flat state; Figure 3b It shows Figure 3a A close-up view of the central area of ​​the upper edge region of the upper panel of the main body of the mask; Figure 4a It shows Figure 3a Front view of the middle panel of the main body of the mask; Figure 4b It shows Figure 4a A close-up view of the central area of ​​the upper edge region of the middle panel; Figure 5a It shows Figure 3a Rear view of the lower panel of the main body of the mask; Figure 5b It shows Figure 5a A close-up view of the lower edge area of ​​the lower panel; and Figures 6a to 6d An alternative embodiment of a respirator mask is shown, which includes an array of reinforcing ribs on the upper and lower panels to prevent buckling. Detailed description

[0037] Figure 1 A folded, flat, maintenance-free respirator mask 100 is shown in its unfolded and open states, just as it would be when worn by a user. The mask 100 includes an upper panel 102, a middle panel 104, and a lower panel 106, which together define a nasal and oral body portion for covering the wearer's nose and mouth when the mask is unfolded and open. The upper panel 102 defines an upper edge region 108 for contacting the wearer's face below the eyes during wear, and the lower panel 106 defines a lower edge region 110 for contacting the wearer's jaw and throat, such that the wearer's chin is accommodated within the mask.

[0038] Each of panels 102, 104, and 106 comprises multiple layers: an outer layer; at least one filter layer for capturing potentially harmful gas or vapor particles in response to the wearer's inhalation or exhalation; and an inner layer. The outer layer is suitably a spunbond polypropylene material with a density of approximately 50 g / m² (gsm). The outer layer protects the underlying layers from abrasion, tearing, or contamination. Below the outer layer is a set of meltblown polypropylene filter layers, which vary in weight and number between different variants of the respirator depending on the application and filtration requirements. These layers provide filtration performance through their electrostatic charge, thereby attracting harmful particles as air passes through the respirator and preventing these particles from further entering the wearer's airway. This electrostatic charge can be achieved through electrostatic or hydrostatic means. For disposable respirators, the filter mask (FFP) level is typically in the range of 1 to 3 to provide different levels of protection against particulate hazards. Indicators may be provided on the mask to indicate to the user the level of protection provided by the mask. For example, the elasticity of (one or more) bands can be color-coded to act as an indicator, such as blue for FFP2, orange for FFP3, and so on. Suitably, the number of meltblown polypropylene filter layers can vary between 2 and 5 layers, and the weight can vary between 20 gsm and 40 gsm. Suitably, the weight of the meltblown polypropylene filter layers decreases from the outer layer to the inner layer. The inner layer of the respirator is a layer of spunbond polypropylene, suitably about 30 gsm. The outer layer is relatively soft and provides a comfortable and attractive environment for the wearer. The mask may optionally include a one-way valve (not shown), such as an exhalation valve centrally mounted on the outer surface of the middle panel 104.

[0039] The intermediate panel 104 also includes a structural mesh layer located between the outer layer and the filter layers (one or more). Suitably, the structural layer comprises a polypropylene mesh. This layer is much stiffer than the other layers and is positioned to provide a horizontal structure when the respirator is worn and to prevent denting / collapse during use. The mesh has openings in an area of ​​approximately 4mm × 4mm, which provides structure to the respirator without significantly increasing breathing resistance. This provides the user with an open breathing space, but with a more comfortable and less inhibited breathing experience. This structural layer is placed only across the width of the intermediate panel because the upper and lower panels need to deform in different planes to conform to the wearer's face.

[0040] The middle panel 104 defines an upper edge region 112, along which a corresponding edge region of the upper panel 102 is attached by ultrasonic seam welding to seal the two panels and their laminated materials together along those upper edge regions. The middle panel 104 defines a lower edge region 114, along which a corresponding edge region of the lower panel 106 is attached by ultrasonic seam welding to seal the two panels and their laminated materials together along those lower edge regions. A pair of parallel needle-welded or spot-welded ultrasonic welding lines are provided along the free upper edge region 108 of the upper panel 102 and along the free lower edge region 110 of the lower panel 106 to seal the laminated materials of the upper panel 102 and the lower panel 106 together and prevent abrasion. Needle-welded or spot-welded welding is suitably used along these free edges to provide material flexibility when conforming to the wearer's face. The opposing end regions 116 and 118 of the three panels 102, 104, and 106 are sealed together by spaced and parallel transverse weld lines 120. (Example) Figure 3a As shown, the panels are arranged such that when the main body of the mouth and nose is in a closed and folded flat state, the lower panel overlaps the middle panel and the upper panel overlaps on top of the lower panel, that is, when the main body of the mouth and nose is folded flat, the lower panel is located between the middle panel and the upper panel.

[0041] The ends of a pair of elastic straps 122, 124 are welded to the rear / inner surface of each corresponding end region 116, 118. Suitably, the end of the upper strap of strap 122 is welded to the end region of the upper panel 102, and the end of the lower strap of strap 124 is welded to the end region of the lower panel 106. Optionally, the ends of straps 122, 124 are located between reinforcing strips before being welded to the panels. Suitably, the end regions of the panels and straps are welded together in a single welding operation and under pressure, such that the strap material is at least partially combined with the laminated material of the panels 102, 104, 106 to securely attach the ends of straps 122, 124 to the mouth and nose body portion of the mask. A transverse weld line 120 forms elongated ribs or teeth 122 on the outer surface of the end region of the intermediate panel 104, the elongated ribs or teeth 122 corrugating the strap and panel material to further secure the strap to the mouth and nose body portion of the mask. Ribs or teeth 122 are formed on the outer surface of the middle panel 104 to avoid contact with the wearer's face and to improve grip when holding the end regions 116, 118 of the mouth and nose body portion to wear the mask and / or adjust the position of the mask relative to the wearer's face. The welded end regions 116, 118 also seal the geometry of the mask when open and can be pulled in the opposite direction when the mask is not in use to help fold and close the mask.

[0042] like Figure 2As shown, the free upper edge region 108 of the upper panel 102 includes a centrally located recess or groove segment 126 for contacting and conforming to the wearer's nose. An aluminum nose strip 132 is optionally disposed on or within the outer layer of the upper panel 102 to allow the wearer to maintain a close fit and contact between the upper edge region 108 of the upper panel 102 and the wearer's anterior inner cheek area and nose, ensuring an effective seal between the mask and face during use. The nose strip 132 is suitably fixed to a suitable location on or within the upper panel by ultrasonic welding, adhesives, etc., for example, welding features 131 at least partially surround the perimeter of the nose strip to hold it in place. Suitably, the nose strip is approximately 96 mm long and approximately 5 mm-6 mm wide. Furthermore, a foam strip is optionally disposed on the inner surface of the inner layer and extends along the upper edge region 108 to further mitigate any risk of inward leakage when the wearer inhales. Suitably, the foam strip is formed of a soft-touch compressible foam material.

[0043] like Figure 3a As shown, the mask is displayed in a closed and folded flat state. The upper edge region 108 of the upper panel 102 also includes a first convex peak 128 and a second convex peak 130 located on a first side and a second side of the recessed groove section 126, respectively. The shape and size of the first peak 128 and the second peak 130 are designed to contact and fit closely to the front inner cheek area of ​​the wearer's face on each side of their nose, ensuring a consistent and effective seal between the mask and the face generally along the upper edge region 108 of the upper panel 102, while also providing the maximum amount of filter material in this region of the upper panel 102 to improve filtration performance and breathability.

[0044] like Figure 3bAs shown, each convex peak segment 128, 130 defines a curved apex. The radius of curvature of each peak segment is approximately 20mm-40mm, and preferably approximately 26mm. The convex peak segments 128, 130 smoothly transition into each side 138, 140 of the groove segment 126, wherein each side of the groove segment is generally curved. The radius of curvature of each side of the groove segment is approximately 20mm-40mm, and preferably approximately 29mm. The base 139 of the groove segment 126 is slightly concave, but may be straight, i.e., not curved. The radius of curvature of the base of the groove segment is approximately 200mm-300mm, and preferably approximately 240mm. Preferably, the depth of the groove segment along the central vertical plane from the base of the groove segment to the horizontal tangent connecting the first and second peak segments is approximately 4mm-10mm, and preferably approximately 5mm. Preferably, the base of the groove segment extends equally in opposite directions from the central vertical plane for approximately 10mm-15mm. Suitablely, the first and second peak segments define a spacing of approximately 45mm-75mm, i.e., the distance between the apexes of the first and second peak segments, and the spacing is suitablely approximately 55mm-65mm. Then, each side segment 146, 148 of the upper edge region 108 of the upper panel 102 is inclined away from the corresponding peak segment 128, 130 toward the corresponding end region 116, 118 of the panel. Each side segment 146, 148 is slightly convex and has a radius of curvature of approximately 1600mm-1700mm and suitablely approximately 1645mm-1655mm. Alternatively, each side segment can be straight. Figure 3b Viewed from the left-hand side, the central region of the upper edge region 108 of the upper panel 102 defines seven distinct segments 142, 128, 138, 126, 140, 130, and 144, wherein at least the peak segments 128 and 130 have a different curvature direction than the groove-side segments 138 and 140. Preferably, each of the seven segments is curved. The variation (i.e., increase or decrease) in the slope direction along the upper edge region is determined by... Figure 3b The seven inflection points shown are 141, 143, 145, 147, 149, 151, and 153.

[0045] The upper edge region 108 of the upper panel 102 includes a pair of parallel weld lines 150, each weld line 150 including spaced pin welds or spot welds to seal the layers of the panel together, and also provides some flexibility along the edge region to allow the edge region to closely conform to the contours of the wearer's face, thereby preventing gaps and thus preventing leakage paths.

[0046] like Figure 4aAs shown, the upper edge region 112 of the middle panel 104 includes a peak segment 152 centrally located between a first side edge segment 154 and a second side edge segment 156. The first side edge segment 154 and the second side edge segment 156 slope in opposite directions from their respective sides toward their respective end regions 116, 118 of the middle panel 104. The peak segment 152 of the middle panel 104 is generally convex and has a radius of curvature of approximately 200 mm to 220 mm, but may be straight, i.e., uncurved, to define a generally flat "table-top" peak segment. Suitably, the peak segment 152 of the middle panel has a width of approximately 40 mm to 60 mm and a height of approximately 5 mm. Each of the first side edge segment 154 and the second side edge segment 156 of the upper edge region 112 of the middle panel 104 is concave to define a swept tapered edge from the proximal side of each side of the central peak segment 152 to each corresponding end region 116, 118 of the panel. Each side 158, 160 of the peak segment 152 is generally convex, and each of the first side edge segment 154 and the second side edge segment 156 is connected to each corresponding side 158, 160 of the peak segment 152 by a corresponding concave transition segment 162, 164, the radius of curvature of which is smaller than that of the first side edge segment 154 and the second side edge segment 156. Suitablely, the convex sides 158 and 160 of the peak segment each have a radius of curvature of approximately 15mm-20mm, suitablely approximately 16.5mm, and the concave transition segments 162 and 164 each have a radius of curvature of approximately 20mm-35mm, suitablely approximately 28.5mm. This arrangement smoothly transitions the swept-side edge segments 154 and 156 into the central peak segment 152. Desiredly, when the mask is worn, the contour of the upper edge region 112 of the intermediate panel 104 improves the wearer's vision. Moving laterally along the Y-axis from the central "Z-plane" towards either end region of the mask in either direction, the upper edge region 112 gradually tapers to reduce peripheral and central visual obstruction, thereby increasing the wearer's visible area. This upper edge contour of the intermediate panel 104 also adapts to eyeglasses to allow them to be worn comfortably without colliding with the mask, and also maximizes the filtration area of ​​the intermediate panel and allows for lower breathing resistance.

[0047] like Figure 4b As shown, viewed from left to right, the upper edge region 112 of the middle panel 104 defines seven distinct segments 154, 162, 158, 152, 160, 164, and 156, wherein at least the convex side segments 158 and 160 of the central peak segment 152 have a different curvature direction than the concave transition segments 162 and 164. Preferably, each of the seven segments is curved. The change (i.e., increase or decrease) in the slope direction along the upper edge region is determined by... Figure 4bThe seven inflection points shown are 155, 157, 159, 161, 163, 165, and 167.

[0048] The intermediate panel 104 includes a lower edge region 114 along which a lower panel is attached, and the lower edge region 114 is contoured differently from the upper edge region 112 of the intermediate panel 104, such that the intermediate panel is asymmetrical about a horizontal central axis. The lower edge region 114 includes a central convex segment 166 with a radius of curvature of approximately 90 mm, located between generally straight side segments 168, 170 extending to the end regions 116, 118 of the panel. Alternatively, the side segments 168, 170 may be slightly concave and include at least one concave segment. Suitably, each side segment 168, 170 may include an inner concave segment with a radius of curvature of approximately 635 mm and an outer concave segment with a radius of curvature of approximately 515 mm. Either arrangement maximizes the filtration area of ​​the intermediate panel and allows for lower breathing resistance. The height of the middle panel 104 along the central vertical plane or "Z-axis" is approximately 85 mm, and the width of the middle panel 104 along the central horizontal plane or "Y-axis" (including its end regions 116, 118) is approximately 210 mm. The depth of the lower edge region 110 is approximately 30 mm.

[0049] like Figure 5a and Figure 5b As shown, the lower edge region 110 of the lower panel 106 includes a centrally located recessed section 172 situated between a first convex peak 174 and a second convex peak 176 extending toward the corresponding end regions 116, 118 of the lower panel 106. The recessed section 172 is configured to adapt to and conform to the wearer's throat region below the chin when the mask is worn, to improve comfort and prevent irritation. The centrally located recessed section 172 is generally concave and has a radius of curvature of approximately 41 mm, a depth of approximately 1.4 mm, and a width of approximately 14 mm. Each convex peak 174, 176 of the lower edge region 110 has a radius of curvature of approximately 52.5 mm and a width of approximately 20 mm. Each side edge of the lower edge region 110 includes at least one convex side segment 178, 180 that sweeps smoothly from each convex peak segment 174, 176 toward the corresponding end region 116, 118. Each side edge of the lower edge region 110 may also include a generally straight or additional convex segment 186, 188 connecting each outer convex side segment 178, 180 to the corresponding convex peak segment 174, 176. Suitably, each side edge includes a concave side segment 182, 184 connecting the corresponding convex side segment 178, 180 to the corresponding end region 116, 118.

[0050] like Figure 5bAs shown, viewed from left to right, the lower edge region 110 of the lower panel 106 defines nine distinct segments 182, 178, 186, 174, 172, 176, 188, 180, and 184. Suitablely, at least seven of these segments are curved. The variation (i.e., increase or decrease) along the slope direction of the lower edge region is determined by… Figure 5b The eight inflection points shown are 173, 175, 177, 179, 181, 183, 185, and 187.

[0051] To assist the wearer in putting on or taking off the mask, the upper panel 102 and / or the lower panel 106 may include one or more handle regions for the wearer to grip when opening the mask and fitting it over the nose and mouth. For example, the upper panel 102 may include a material loop for positioning fingers below it or a folded material tab for pinching between the fingers and thumb. The mask may also include means for adjusting the length of the straps or each strap attached to the mask to accommodate different anatomy of the wearer. While the straps are preferably welded to the inner surface of each end region 116, 118 of the mask, the straps may be welded to the outer surface of the end region of the intermediate panel 104. Alternatively, the straps or each strap may be attached to the mask body via a folded textile loop attached to each end region of the mask, and the straps or each strap may be a continuous strap passing through each textile loop. Further alternatively, the straps or each strap may be a continuous annular strap passing through a slot in each end region of the mask body.

[0052] like Figures 6a to 6dAs shown, the upper panel 602 and / or lower panel 606 of the mask 600 may include an array of longitudinally extending and laterally spaced elongated reinforcing elements or regions 650 to increase the longitudinal (front-to-back) bending stiffness of the respective panels in their central regions. Suitably, the reinforcing elements or regions are weld lines created, for example, by ultrasonic welding. Each weld line forms a rib that acts as a reinforcement / bending stiffener. The addition of these ribs creates rigid regions, which are desirablely advantageous for both the upper and lower panels to prevent the panel material from buckling or wrinkling when the mask is worn, particularly in the central region. Otherwise, such buckling effect is caused by tension in the straps, which pulls the middle panel 604 toward the wearer's face and undesirably impairs the mask's filtration performance. The ribs are positioned along lines of incident force to create rigid regions, thereby preventing this undesirable buckling in the longitudinal (front-to-back) direction while allowing the respective panels to fit laterally around the nose or chin. An alternative method to increase bending strength and rigidity in one or both of the central regions of the upper and lower panels could be to attach a second layer of material to the outer surfaces of the upper and / or lower panels in the central regions of the upper and / or lower panels by weld lines around the perimeter of the second layer, thereby doubling the material thickness in those central regions. However, this would undesirably increase breathing resistance in these regions and could potentially cause discomfort to the wearer. Uniformly spaced weld lines allow inhaled and exhaled air to pass through the material between the weld lines, eliminating the need for a double layer to increase stiffness / rigidity and without significantly increasing breathing resistance. The weld lines are suitably longest on and near the central axis of the mask and decrease in length toward the outer edge of the weld line array to form a generally triangular weld line array. Suitably, the upper end of each weld line on the upper panel is angled to define a bend line. Similarly, the lower end of each weld line on the lower panel is angled to suitably define a bend line. Suitably, the relatively wide area of ​​the weld line array on the upper panel 602 generally corresponds in width to the peak segment 652 of the upper edge region 612 of the intermediate panel 604. Suitably, the relatively wide area of ​​the array of weld lines on the lower panel 606 can roughly correspond in width to the wearer's chin. When the mask is worn, the position and arrangement of the reinforcing weld lines 650 allow the remaining "unstructured" areas of the upper and lower panels to fit snugly against the wearer's facial geometry in an effective and efficient manner, particularly around the nose and chin, while preventing these central areas of the upper and lower panels from buckling. Suitably, gaps are provided between the upper edge region 612 of the intermediate panel 604 and the reinforcing weld lines 650 on the upper panel 602, and / or between the lower edge region 614 of the intermediate panel 604 and the reinforcing weld lines 650 on the lower panel 606. This arrangement creates a flexible area at this joint, allowing the material of the upper and / or lower panels to locally bend when the mask is opened for ease of wear.

[0053] Therefore, certain embodiments of the present invention provide a maintenance-free, foldable, flat respirator mask that fits snugly to the wearer's face, particularly around the nose and cheek areas, to prevent or at least minimize the risk of leakage gaps. The mask is comfortable to wear and easy to put on and take off. The mask allows the wearer to wear glasses properly and comfortably without adversely affecting the function of any piece of personal protective equipment (PPE), and the mask is constructed not to impair or restrict the wearer's field of vision.

Claims

1. A respirator mask, comprising: The main body of the mouth and nose defines an upper edge region, which includes a first peak segment and a second peak segment. When the mask is worn, the first peak segment and the second peak segment can respectively fit and contact the first and second anterior inner cheek regions of the wearer's face. The first peak segment and the second peak segment are respectively located on the first and second sides of a centrally located groove segment. When the mask is worn, the groove segment can fit and contact the wearer's nose.

2. The respirator mask according to claim 1, wherein, The first peak segment, the second peak segment, and the groove segment define at least five inflection points along the upper edge region.

3. The respirator mask according to claim 2, wherein, The upper edge region is defined by at least seven inflection points.

4. The respirator mask according to any one of the preceding claims, wherein, The groove is generally concave.

5. The respirator mask according to any one of the preceding claims, wherein, The depth of the groove segment along the central vertical plane from the base of the groove segment to the horizontal tangent connecting the first peak segment and the second peak segment is approximately 4 mm to 10 mm.

6. The respirator mask according to claim 5, wherein, The depth of the groove is approximately 5 mm.

7. The respirator mask according to claim 5 or 6, wherein, The base of the groove segment extends equally from the central vertical plane in opposite directions for about 10 mm to 15 mm.

8. The respirator mask according to any one of the preceding claims, wherein, The first peak segment and the second peak segment define a spacing of approximately 45 mm to 75 mm.

9. The respirator mask according to claim 8, wherein, The spacing is approximately 55mm to 65mm.

10. The respirator mask according to any one of the preceding claims, wherein, The main body of the mouth and nose includes a filter material for capturing potentially harmful gas or vapor particles in response to the wearer's inhalation or exhalation.

11. The respirator mask according to any one of the preceding claims, wherein, The mouth and nose body portion can be folded flat when the mask is removed, and the mouth and nose body portion includes a plurality of connected panels, the plurality of connected panels including an upper panel that defines the upper edge region when the mask is worn.

12. The respirator mask according to claim 11, wherein, The plurality of panels include a lower panel that is positioned below the wearer's chin when the mask is worn, and a middle panel that is connected to the upper panel that is positioned in front of the wearer's mouth when the mask is worn.

13. The respirator mask according to claim 12, wherein, When the main body of the mouth and nose is folded flat, the lower panel is located between the middle panel and the upper panel.

14. The respirator mask according to claim 12 or 13, wherein, The intermediate panel includes an upper edge region, the upper panel is attached along the upper edge region of the upper panel, and the upper edge region of the upper panel includes a peak segment centrally disposed between a first side edge segment and a second side edge segment of the upper edge region, the first side edge segment and the second side edge segment sloping away from the corresponding side of the centrally disposed peak segment in opposite directions toward the corresponding end region of the intermediate panel.

15. The respirator mask according to claim 14, wherein, The upper edge region of the middle panel defines at least six inflection points.

16. The respirator mask according to claim 14 or 15, wherein, The centrally located peak of the middle panel has a width of approximately 40 mm to 60 mm.

17. The respirator mask according to any one of claims 14 to 16, wherein, The centrally located peak of the middle panel is convex and has a radius of curvature of approximately 200 mm to 220 mm.

18. The respirator mask according to any one of claims 14 to 17, wherein, Each of the first side edge segment and the second side edge segment is concave.

19. The respirator mask according to any one of claims 14 to 18, wherein, Each of the first side edge segment and the second side edge segment is connected to the centrally located peak segment via a corresponding transition segment, each of the transition segments comprising a concave transition segment with a radius of curvature smaller than that of the first side edge segment and the second side edge segment.

20. The respirator mask according to claim 19, wherein, The radius of curvature of each concave transition section is approximately 20 mm to 35 mm.

21. The respirator mask according to any one of claims 14 to 20, wherein, The middle panel includes a lower edge region, along which the lower panel is attached, and the contour of the lower edge region differs from that of the upper edge region of the middle panel, such that the middle panel is asymmetrical about a horizontal axis.

22. The respirator mask according to any one of claims 12 to 21, wherein, The lower panel includes a lower edge region, and the lower edge region of the lower panel includes a centrally located recessed section, which can fit and contact the wearer's throat area when the mask is worn.

23. The respirator mask according to claim 22, wherein, The centrally located recessed section of the lower edge region is located between a first convex section and a second convex section extending toward the corresponding end region of the lower panel.

24. The respirator mask according to any one of the preceding claims, comprising at least one strap for securing the mask to the wearer's head.

25. The respirator mask according to any one of the preceding claims, comprising at least one exhalation valve.

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