Strap fastening system for a disposable respirator providing improved donning

1. A disposable respirator adapted to be placed on a head of a user, the disposable respirator comprising:

a main body made of a non-woven material, the main body being in a pre-formed cupped configuration to cover, in a tight sealing arrangement, a mouth and a nose of the user of the disposable respirator and filter at least a portion of one constituent in air, the main body having a first side of the main body and a second opposing side of the main body;

a first pull-strap fastening component and a second pull-strap fastening component formed separately from the main body, each of the first pull-strap fastening component and the second pull-strap fastening component being formed by molding thermoplastic polymers, the first pull-strap fastening component being attached to the first side of the main body and the second pull-strap fastening component being attached to the second opposing side of the main body;

each of the first pull-strap fastening component and the second pull-strap fastening component comprising a first slot and an associated second slot, each of the first slots being generally parallel to the associated second slot, each of the first pull-strap fastening component and the second pull-strap fastening component having a plurality of integrally formed teeth extending into each of the first slot and the second slot, each of the second slots having a greater number of teeth than each of the first slots, each of the teeth of each of the second slots having pointed ends, each of the teeth of each of the first slots having rounded ends, the teeth extending into each of the first slots being disposed in a direction opposite from the teeth extending into each of the associated second slots, the second slot being located laterally closer to an ear of the user than the first slot; and

a strap defined by a closed loop of elastic material, the strap being connected to the first pull-strap fastening component and the second pull-strap fastening component, wherein the second pull-strap fastening component comprises an adjustment means that can be adjusted to fit the disposable respirator to the user's head and the strap is adapted to encircle the user's head by being adjustably looped through the first slot of the first pull-strap fastening component and configured to extend back around the user's head to the second pull-strap fastening component where an overlapped portion of the strap is adjustably threaded through both the first and the second slots of the second pull-strap fastening component, the strap having a width between 2 cm and 3 cm, the strap having a retraction force range of about 30 grams force to about 100 grams force per centimeter in width at 100% elongation after having been extended to 133% elongation,

each of the first and the second slots of the first pull-strap fastening component and the second pull-strap fastening component have a width and a length, the width being between 1.0 mm and 1.5 mm as measured from the ends of each of the respective teeth to an opposing side of respective ones of the slots, the length of each of the first and the second slots of the first pull-strap fastening component and the second pull-strap fastening component being between about 25% and about 125% of the width of the strap.

2. The disposable respirator as set forth in claim 1 wherein the strap has a first portion configured to be located over the user's ear and about an upper area of the user's head and a second portion configured to be located under the user's ear and about a lower area of the user's head.

3. The disposable respirator as set forth in claim 1 wherein the first pull-strap and the second pull-strap fastening components further comprise a third slot, and a fourth slot, the first slot being located longitudinally from the third slot, the second slot being located longitudinally from the fourth slot, wherein the second slot and the fourth slot are located laterally closer to the user's ear than the first slot and the third slot.

4. A disposable respirator comprising:

a main body made of a non-woven material, the main body being in a pre-formed cupped configuration to cover, in a tight sealing arrangement, a mouth and a nose of the user of the disposable respirator and filter at least a portion of one constituent in air, the main body having a first side of the main body and a second opposing side of the main body;

a first pull-strap fastening component formed separately from the main body by molding thermoplastic polymers, the first pull-strap fastening component being attached to the first side of the main body, the first pull-strap fastening component having a first slot and an associated second slot generally parallel to the first slot, the second slot being located laterally closer to an ear of the user than the first slot when the disposable respirator is donned by the user;

a second pull-strap fastening component formed separately from the main body by molding thermoplastic polymers, the second pull-strap fastening component being attached to the second side of the main body, the second pull-strap fastening component having a first slot and an associated second slot generally parallel to the first slot, the second slot being located laterally closer to the user's ear than the first slot when the disposable respirator is donned by the user;

each of the first pull-strap fastening component and the second pull-strap fastening component having a plurality of integrally formed teeth extending into the first slot and the second slot, each of the second slots having a greater number of teeth than each of the first slots, each of the teeth of each of the second slots having pointed ends, each of the teeth of each of the first slots having rounded ends, the teeth extending into each of the first slots being disposed in a direction opposite from the teeth extending into each of the associated second slots,

a strap defined by a closed loop of elastic material, the strap being adapted to encircle a head of the user when the disposable respirator is donned by the user, the strap being looped through the first slot in the first pull-strap fastening component, an overlapped portion of the strap being threaded through both the first slot and second slot in the second pull-strap fastening component, the strap having a width between 2 cm and 3 cm, the strap having a retraction force range of about 30 grams force to about 100 grams force per centimeter in width at 100% elongation after having been extended to 133% elongation, and each of the first slots and the second slots of the first pull-strap fastening component and the second pull-strap fastening component have a width and a length, the width being between 1.0 mm and 1.5 mm as measured from the ends of each of the respective teeth to an opposing side of respective ones of the slots, the length of each of the first slots and the second slots of the first pull-strap fastening component and the second pull-strap fastening component being about 25% and about 125% of the width of the strap.

5. The disposable respirator as set forth in claim 4 wherein the strap has a width of about 2.5 cm.

6. The disposable respirator as set forth in claim 5 wherein the strap has a first portion configured to be located above the user's ear and about an upper area of the user's head and a second portion configured to be located under the user's ear and about a lower area of the user's head.

7. A disposable respirator comprising:

a main body made of a non-woven material, the main body being in a pre-formed cupped configuration to cover, in a tight sealing arrangement, a mouth and a nose of the user of the disposable respirator and filter at least a portion of one constituent in air, the main body having a first side of the main body and a second opposing side of the main body;

a first pull-strap fastening component formed separately from the main body by molding thermoplastic polymers, the first pull-strap fastening component being attached to the first side of the main body, the first pull-strap fastening component having at least one slot;

a second pull-strap fastening component formed separately from the main body by molding thermoplastic polymers, the second pull-strap fastening component being attached to the second side of the main body, the second pull-strap fastening component having a first slot, an associated second slot and teeth extending into each of the first slot and the second slot, the teeth extending into the first slot being disposed in a direction opposite from the teeth extending into the second slot, the second slot having a greater number of teeth than the first slot; each of the teeth of the second slot having pointed ends, each of the teeth of the first slot having rounded ends, and

a strap adapted to encircle a head of the user when the disposable respirator is donned by the user, the strap being defined by a closed loop of elastic material, the strap being looped through the at least one slot in the first pull-strap fastening component and an overlapped portion of the strap being threaded through the first slot and the second slot in the second pull-strap fastening component such that the teeth extending into each of the slots of the second pull-strap fastening component engage the overlapped portion of the strap,

wherein the strap has a width between 2 cm and 3 cm, the strap having a retraction force range of about 30 grams force to about 100 grams force per centimeter in width at 100% elongation after having been extended to 133% elongation, and

the first slot and the second slots of the second pull-strap fastening component having a width and a length, the width being between 1.0 mm and 1.5 mm as measured from the ends of each of the respective teeth to an opposing side of respective ones of the slots, the length of each of the first and second slots of the second pull-strap fastening component being about 25% and 125% of the width of the strap.