WO2021222481A1 - Antipathogen respirator - Google Patents

Abstract

Embodiments described herein can include a respirator that provides pathogen exposure protection and that can be easily sterilized and reused. Embodiments described herein also include a respirator that can disable pathogens via a polymer layer defining apertures for air flow and having antiviral materials deposited on a polymer layer proximate the apertures. Embodiments described herein also include structures defining flaps therein wherein flaps have an antiviral material on at least a portion of their surface and the flaps are configured to flex at least one of inward or outward in response to force on the flaps caused by air flow during at least one of inhaling or exhaling while the mask is being worn.

Description

ANTIPATHOGEN RESPIRATOR RELATED APPLICATIONS [0001] This application claims the benefit of United States Provisional Application No. 63/016,441, filed on April 28, 2020, entitled “Antipathogen Protective Facial Mask with Active Electronics Options”, and United States Provisional Application No.63/142,422, filed on Jan.27, 2021, entitled “PLANAR ANTI-PATHOGEN STRUCTURE SUSPENDED WITHIN THE AIR FLOW PATH WITHIN A PROTECTIVE FACIAL MASK OR RESPIRATOR”, both of which are hereby incorporated herein by reference. BACKGROUND [0002] Traditional respirator facial masks used for medical situations range from basic cloth patches that cover the mouth and nose, to more elaborate formed structures that have fibrous structures that create a filter effect for air that is breathed in by the user as well as exhaled by the user. In some cases, the filter effect is directed at protecting the user from inhaled pathogens or contaminants, and in some cases the intent is to prevent the user from exhaling pathogens or infections particles. In general, most commercially available respirators are intended for a one time use and discarded. They are difficult or expensive to sterilize and return to as new condition. In addition, most if not all commercially available respirators are designed and used to reduce exposure to pathogens and do not attack the potential pathogens themselves. BRIEF DESCRIPTION [0003] Embodiments described herein can include a respirator that provides pathogen exposure protection and that can be easily sterilized and reused. Embodiments described herein also include a respirator that can disable pathogens via a polymer layer defining apertures for air flow and having antiviral materials deposited on a polymer layer proximate the apertures. Embodiments described herein also include structures defining flaps therein wherein flaps have an antiviral material on at least a portion of their surface and the flaps are configured to flex at least one of inward or outward in response to force on the flaps caused by air flow during at least one of inhaling or exhaling while the mask is being worn. DRAWINGS [0004] Understanding that the drawings depict only exemplary embodiments and are not therefore to be considered limiting in scope, the exemplary embodiments will be described with additional specificity and detail through the use of the accompanying drawings, in which: [0005] FIGs.1A and 1B are perspective views of an example respirator that is reusable and easy to sterilize; [0006] Fig.2A is a front view and Fig.2B is a cross-sectional view of the main body of the respirator of FIGs.1A and 1B; [0007] FIGs.3A, 4A, and 5A are cross-sectional views of portions of example polymer layers for use in the respirator of Figs.1A and 1B; [0008] Fig.s 3B, 4B, and 5B are illustrations showing example shapes of the apertures looking downward into the apertures of their respective cross-sectional views in FIGs.3A, 4A, 5A. [0009] FIG.6A is a cross-sectional view of an example polymer layer for use in the respirator of FIGs.1A and 1B; [0010] FIG.6B is an illustration showing an example shape of the aperture looking downward into the aperture of FIG.6A; [0011] FIGs.7A-D are cross-sectional views and top illustrations of another example process of creating a high aspect ratio aperture in a polymer layer for use in the respirator of FIGs.1A and 1B; [0012] FIGs.8A-D are cross-sectional views and top illustrations of an example process of using a plurality of polymer layers to create tortuous air passageways through the respirator of FIGs. 1A and 1B; [0013] FIGs.9A and 9B are front and cross-sectional views of an example respirator formed from a stack of polymer layers; [0014] FIGs.10A and 10B are a cross-section and top illustration of an example polymer layer that can be used in a stack of polymer layers; [0015] FIGs.11A and 11B are a cross-section and a top illustration of another example polymer layer that can be used in a stack of polymer layers; [0016] FIGs.12A and 12B are a front view and a cross-sectional view of an example respirator 1200 having embedded ultraviolet LEDs therein; [0017] FIGs.13A and 13B are a cross-sectional view and top view of another example stack of polymer layers forming tortuous air passageways therethrough for use in a respirator; [0018] FIG.13C is a cut-away view of another example stack of polymer layers having flaps defined therein; [0019] FIGs.14A and 14B are a cross-sectional view and top view of yet another example stack 1400 having a plurality of slits formed in metal bearing films on respective polymer layers; [0020] FIG.14C is a cut-away view of another example stack having slits cut therein; [0021] FIG.15A and 15B are a cross-sectional view and top view of still another example stack having a plurality of slits defined in fish-scale type pattern; [0022] FIG.15C is a cross-sectional view of another example stack having a fish-scale type pattern of slits; [0023] FIGs.16A-D are cross-sectional and top views of yet another example process and stack; [0024] FIG.17 is an exploded view of an example stack defining horizontal passageways having exposed antiviral surfaces through which the air flow is directed; [0025] FIG.18A is front view of an example respirator having tortuous air passages formed in polymer layers that are contiguous with the main body; [0026] FIG.18B is a cross-sectional view of a respirator having an exchangeable cartridge removably secured thereto; [0027] FIGs.19A-C are a front view and two cross-sectional views of another example respirator having a cartridge with a stack of polymer layers; [0028] FIGs.20A and 20B are front views of an example respirator having a polymer strap attached thereto; [0029] FIGs.21A-C are a front view, an enlarged view, and a cross-sectional view of an example respirator having relief cuts defined therein; [0030] FIGs.22A and 22B are a front view and a cross-sectional view of an example off-the- shelf respirator having a cartridge formed of a plurality of polymer layers as described herein attached thereto; [0031] FIGs.23A-C are front views and a cross-sectional view of an example respirator having a strap with embedded circuits therein; [0032] FIGs.24A and 24B are cross-sectional views of yet another example respirator having batteries embedded in the straps and light pipes for delivering the light to the air chamber; [0033] FIGs.25A-C are front views and cross-sectional views of a respirator that combines the filter effects of a traditional N95 or KN95 type facial mask and the benefits of the stacked polymer layers; [0034] FIGs.26A-D are perspective views of another example respirator having a cartridge including a stack of polymer layers defining tortuous air passageways; [0035] FIGs.27A and 27B are exploded views of an example cartridge for use in any of the cartridge respirators; [0036] FIG.28 is another example of a main body of a respirator having a fit tester port; [0037] FIGs.29A and 29B are a front view and a cross-sectional view of another example of a cartridge for use in a respirator configured for such a cartridge; [0038] FIGs.30A and 30B are cross-sectional views of an example of a cloth stack that can be used as filter material in a cartridge or in a main body of a respirator; [0039] FIG.31 is a cross-sectional view of a filtering portion that can be used in a cartridge or in a main body of a respirator; [0040] FIGs.32A-C are front views of example components for the filtering portion of FIG.31; [0041] FIG.33 is a cross-sectional view of another example filtering portion that can be used in a cartridge or in a main body of a respirator; [0042] FIG.34A is a front view of the copper flex layer of FIG.33; [0043] FIG.34B is a front view of the pinwheel spacer layer of FIG.33; [0044] FIG.34C is a side cross-sectional view of the filter portion of FIG.33 illustrating its concave shape; [0045] FIGs.35A-C are a front view, an enlarged view, and a cross-sectional view of another example copper flex layer for use in the filtering portion described with respect to FIGs.33 and 34; and [0046] FIGs.36A-F are other example respirators having cartridges that can be secured thereto. DETAILED DESCRIPTION [0047] Figures 1A and 1B are perspective views of an example respirator 100 that is reusable and easy to sterilize. Respirator 100 includes a main body 102 having or more straps 104 extending therefrom. The main body 102 defines an interior cavity 106 and is configured to cover a mouth and a nose of a user. In this example, the main body 102 is generally rigid and the interior cavity 106 is sized such that the user’s nose fits within the cavity 106. In this example, the main body 102 has a generally concave geometry defining a single depression large enough to cover both the user’s nose and mouth. The one or more straps 104 are configured to hold the respirator onto the face of the user. In this example, the one or more straps 104 are configured to wrap around the ears of the user, but other straps can be used such as one or more straps extending around the back of the user’s head. In use, the respirator 100 is configured to be placed over the mouth and nose of a user such that the outer rim 108 of the main body 102 contacts the user’s face around the mouth and nose. The respirator 100 is constructed such that it can be easily sanitized and reused multiple time. [0048] Figure 2A is a front view and Figure 2B is a cross-sectional view of the main body 102. In an example the main body 102 is composed of a polymer that provides the rigidity for the main body 102 to maintain its geometry. Any suitable thermoelastic polymer can be used for the main body 102 such as liquid crystal polymer (LCP), polyimide, polyolefin, and others. Liquid Crystal Polymer (LCP) is a thermoplastic material that can be shaped, formed, and molded. It is impervious to moisture and is biocompatible. [0049] The polymer has a plurality of apertures 202 defined therein that act as passages for air to pass between the interior cavity 106 and the external environment while the respirator 100 is being worn. Accordingly, the passages provide a path for a user’s breath to enter and exit the interior cavity 106 as the user inhales and exhales while wearing the respirator 100. In an example, one or more surfaces of the main body 102 proximate the plurality of apertures are composed of one or more exposed antiviral materials, such that as the air is passing between the interior cavity 106 and the external environment the air is directed against the exposed antiviral material. Directing the air flow against the exposed antiviral material can cause pathogens into the air flow to contact the antiviral material, which will then disable the pathogens, such that they are destroyed or otherwise rendered inactive. As used herein an antiviral material is a material that is effective at disabling, killing, and/or destroying viruses and microbes, such as bacteria and other microorganisms. In this way, the respirator 100 is configured to direct the air flow between the interior cavity 106 and the external environment, such that the air comes into contact with exposed antiviral material as it is flowing through the passages, thereby disabling pathogens in that air. In an example, the respirator 100 can be configured to direct incoming and outgoing air through the same passages, such that both incoming and outgoing air is subject to the disabling properties of the antiviral material. In an example, the antiviral material can include one or more of silver or copper. In an example, the passages through the main body 102 can be sufficiently tortuous and small that pathogens are also captured as the air passes through the main body 102. For example, the passages can capture sufficient pathogens that the respirator meets the N95 or KN95 standard for respirators in the United States of America. The pattern of apertures shown in Figure 2A is exemplary only. It should be understood that many other suitable patterns of apertures can be used. In an example, the apertures and pattern are much smaller in size than can be seen with the eye. [0050] In an example, substantially all of the main body 102 can have apertures providing air passages between the interior chamber 106 and the external environment defined therein. In other examples, one or more first portions of the main body 102 can have apertures therein, and one or more second portions can have not such apertures therein, such that the air flow is directed through the one or more first portions and is blocked by the one or more second portions. [0051] In any case, at least the portion(s) having the apertures therein can be formed of one or more layers of polymer as described below. In an example, all of the main body 102 can be formed of one or more contiguous layers of polymer. In other examples only a portion of the main body 102 (such as the portion(s) of the main body 102 having apertures) can be formed of the one or more contiguous polymer layers and other portions can be formed of other materials, in other manners, or of distinct layers of polymer. [0052] Figures 3A, 4A, and 5A are cross-sectional views of portions of example polymer layers 302, 402, 502 for use in respirator 100. Each polymer layer 302, 402, 502 has a plurality of apertures 304, 404, 504 defined therein. Figures 3B, 4B, and 5B are illustrations showing example shapes of the apertures 304, 404, 504 looking downward into the apertures 304, 404, 504 of their respective cross-sectional view 3A, 4A, 5A. [0053] In an example, the polymer layers 302, 402, 502 are formed by extrusion and are initially flat. In an example, the polymer layers 302, 402, 502 are initially between 1 and 1000 microns thick and can have any suitable length and width. The creation of the apertures 304, 404, 504 can be accomplished with any of multiple processes such as laser ablation, punching, embossing, plasma etch etc. Each of these processes can have an aspect ratio limitation where the size of the aperture is relative to the thickness of the base polymer layer. With normal processing, a 1:1 aspect ratio is a general rule, where the aperture in a 25 micron thick layer of polymer drives a 25 micron aperture. Figures 3A and 3B illustrate apertures having a circular shape, Figure 4A and 4B illustrate apertures 404 having a square shape, and Figures 5A and 5B illustrate apertures having a hexagonal shape. Other shapes can also be used. [0054] For use in a facial mask application, a 25 micron aperture is too large for effective filtering of particulates and pathogens. Typical N95 masks are rated for 95% filtering of particles of 1 micron or smaller in size. The fiber matrix used to fabricate existing N95 masks create a torture path for air exchange to be restricted and a large percentage of particulates to encounter a restriction and be captured or prevented from passage to the user during inhale and expelled to the atmosphere during exhale. [0055] Figure 6A is a cross-sectional view of an example polymer layer 602 for use in respirator 100. Layer 602 defines a plurality of higher aspect ratio apertures 604 as compared to apertures 304, 404, 504. Figure 6B is an illustration showing an example shape of the aperture 604 looking downward into the aperture 604. The apertures 604 are formed by etching an aperture sized target in a very thin layer of an antiviral material (e.g., copper) 606 which is applied or deposited onto the base polymer layer. The copper 606 acts as a mask for a laser or plasma process where the polymer material is removed to create the aperture 602 while the copper 606 is not removed or damaged in the aperture creation process. [0056] Figures 7A-D are cross-sectional views and top illustrations of another example process of creating a high aspect ratio aperture 704 in a polymer layer 702. The based polymer layer 706 can start out at a given thickness such as 25 microns, with apertures 708 created with a given process as described above with respect to Figures 3A-5A. Once the apertures 708 are formed, heat and pressure can be applied to the polymer layer 706 to reduce its thickness. The resulting material movement of the polymer invades the opening of the apertures to reduce the width of the aperture. [0057] Figures 8A-D are cross-sectional views and top illustrations of an example process of using a plurality of polymer layers 802 to create tortuous air passageways through the respirator 100. In an example, a plurality of polymer layers having apertures therein as describe above can be stacked together to create tortuous air passageways through the respirator 100. Respective polymer layers 802 can be stacked such that the regions including apertures in the respective layers 802 are generally aligned thereby creating continuous passageways through the stack of polymer layers 802. Although the general regions having apertures are aligned, the individual apertures can be misaligned, such that air is forced to change directions and forced against the surfaces of the layers 802 as is passes through the continuous passageways. In an example, the apertures in the regions of apertures of the layers 802 are disposed such that adjacent apertures are less than half the width of an aperture apart. For example, for apertures of 10 microns in width, adjacent apertures are less than 5 microns apart. This disposition of apertures can help to create continuous tortuous passages through the stack 800 by misaligning apertures in adjacent layers 802. [0058] Misaligning the apertures reduces the width of the effective pathway through the stack 800. The layers 802 can have common or variable aperture sizes and shapes as compared to other layers 802. The layers 802 can be fusion bonded to one another where the polymer layers 802 directly bond to each other under heat and pressure, or a bond layer can be added between the polymer layers 802, or the stack 800 can be bonded outside of the aperture region to leave the aperture bearing layers independent from each other if desired. The torture path desired can be designed to achieve the N95 type requirements for particle restriction. Figure 8C is an exploded perspective view of another example stack 810 of layers 812. [0059] Figures 9A and 9B are front and cross-sectional views of the example main body 102 of respirator 100 formed from a stack 800 of polymer layers as described above. The polymer stack bearing the desired aperture patterns can be thermo formed by applying heat and pressure with appropriate tooling to achieve the final desired mask shape and contour. [0060] The construction described is a passive protective respiratory mask that has advantage over traditional masks due to the properties of the polymer stack and the impervious to moisture properties enabling easy sanitation which is difficult if not impossible with traditional masks. To extent an embodiment takes advantage of the properties of the polymer, the aperture patterns can be metalized to create multiple advantages. Most commercial facial masks are passive and simply restrict airflow while attempting to collect particulates, liquids and pathogens. These conventional masks do not attack or kill the pathogens which can collect within the mask over continued use. [0061] Advantageously, by creating all or a portion of the main body 102 out of polymer with apertures as described above, other features can be added to the respirator 100 to not only enhance the filtering effect of the mask, but also attack the pathogens (e.g., microbials) that may be present within the airstream inhaled or exhaled through the respirator 100. [0062] Figures 10A and 10B are a cross-section and top illustration of an example polymer layer 1002 that can be used in a stack as described above. The base polymer material in the layer 1002 can be treated as a printed circuit dielectric and selectively metalized to add antiviral benefits. Figures 10A and 10B illustrate metallization of the aperture pattern with electroless copper, electrolytic, and plated silver which is antiviral. The plating process also naturally reduces the effective aperture size. [0063] Figures 11A and 11B are a cross-section and a top illustration of another example polymer layer 1102 that can be used in a stack as described above. This example layer 1102 is similar to the layer 1002 of Figure 10A except it additionally includes circuit traces and/or metal planes electrically coupling the metalized apertures. This can electrically couple the apertures together. This option enables mass sterilization instantly when the network is subjected to current sufficient enough to elevate the temperature of the metalized features above the extermination temperature while below the melt temperature of the base polymer. In addition, there may be an advantage considering pathogen termination to have the network activated electrically during use to enhance the lethal effect against the pathogens. These connecting circuits or metalized plans can also be plated with silver to increase the surface area of antiviral regions within the respirator 100. [0064] Figures 12A and 12B are a front view and a cross-sectional view of an example respirator 1200 having embedded ultraviolet LEDs 1202 therein. Layers of polymer can be disposed and bonded to define an air chamber 1204 through which the air flow through the respirator 100 can be directed. One or more ultraviolet LEDs 1202 can be disposed to expose the air in the air chamber 1204 to UV light. Sufficient UV light can be provided to sanitize the incoming and outgoing air volume. Multiple Integrated Circuit and passive devices can be embedded in the polymer layers to control power and provide wireless RF communication. Multiple biological sensors can also be embedded in the polymer layers to perform diagnostic tests and identify presence or absence of pathogens, chemicals, gasses, etc. as well as notify need for cleaning or airflow restriction. The respirator 1200 can define tortuous air passageways between the air chamber 1202 and the interior cavity and/or the external environment, which can include any of the examples described herein. [0065] Figures 13A and 13B are a cross-sectional view and top view of another example stack 1300 of polymer layers forming tortuous air passageways therethrough for use in a respirator described herein. In stack 1300 alternating polymer layers 1302 are plated with an antiviral material, such as silver or copper, in certain regions in which tortuous passages will be created. The metal bearing film is die cut or otherwise processed to create flaps 1304 (shear or slits) in desired locations of the metal bearing film. In an example, the layers 1302 are stacked, such that the die cut regions are generally aligned with spaces between the metal bearing films such that the flaps 1304 that will deflect during pressure or air flow exchange therethrough. Other apertures 1306 as described above can also be included in the layers. Multiple layers can be stacked together and fusion bonded outside of the desired airflow region such that the chamber is controlled. These multiple layers can be offset in many directions and supplemented with many layers to create a high density matrix of air flow restrictions and metal bearing antiviral surfaces. Figure 13C is a cut-away view of another example stack 1310 of polymer layers having flaps defined therein. [0066] Figures 14A and 14B are a cross-sectional view and top view of yet another example stack having a plurality of slits formed in metal bearing films on respective polymer layers. In this example the metal bearing films between the slits can twist in response to air flow therethrough to create the tortuous path and direct the air into contact with the exposed antiviral material. Figure 14C is a cut-away view of another example stack having slits cut therein. [0067] Figures 15A and 15B are a cross-sectional view and top view of still another example stack having a plurality of slits defined in fish-scale type pattern. Figure 15C is a cross-sectional view of another example stack having a fish-scale type pattern of slits. [0068] Figures 16A-D are cross-sectional and top views of yet another example process and stack. In this stack multiple layers of silver-plated LCP that create an air flow direction action to allow for breathable flow with maximum contact with antiviral silver surfaces as well as small hole filter effects. The layers are drawn at 25 microns thick, with the silver bearing and filter layers not bonded in the active areas so that there is opportunity for air contact to the silver surfaces. As shown, some layers have large apertures covering large portions or all of the regions in which tortuous passages are created, enabling the air to flow horizontally through these areas. The layers are bonded at the perimeter to allow for aggregate integration into the overall mask structure. The outer layer of the stack is not plated with silver, and the interior layer closest to the face is not plated with silver to protect against any potential flaking of plating entering the breathable air stream such that any silver particulates would be captured in the respirator. [0069] Any of the features described herein can be mix and matched in adjacent layers and the pattern combinations are almost endless, with the with the basic principle of cutting slits or material separations that allow for air flow but reduce the effective gap to improve filter effect while maximizing the surface contact to the antiviral material exposed on the surface. The net filter and airflow effect can be set by adjusting the pattern and/or size of slits, flaps, or apertures, as well as the number of layers in the stack. The LCP can also be treated with a plasma deposited monomer to create anti-wetting characteristics where desired, as well as microfluidic channels can be added to control and direct fluid or moisture accumulation. Figure 17 is an exploded view of an example stack defining horizontal passageways having exposed antiviral surfaces through which the air flow is directed. [0070] The stack of polymer layers defining tortuous air flow passages can be formed in a polymer material that is contiguous with the main body 102 or can be formed in a cartridge that is removably secured to the main body 102. Figure 18A is front view of an example respirator 1800 having tortuous air passages formed in polymer layers that are contiguous with the main body. Figure 18B is a cross-sectional view of a respirator 1801 having an exchangeable cartridge 1802 removably secured thereto. The cartridge 1802 can include a stack of polymer layers defining tortuous air passageways as described in any of the examples herein. The main body 1804 to which the cartridge is removably secured can also be composed of one or more layers of a thermoelastic polymer or can be composed of another material. In an example, the main body is composed of a see-through (i.e., optically clear) polymer. Forming the tortuous air flow passages in a cartridge 1802 enables the cartridge 1802 to be exchanged with a new cartridge as desired. The cartridge 1802 can be removed, replaced, cleaned, sanitized etc. Although an example size and geometry of cartridge is shown in Figure 18B, cartridge 1802 can have any suitable size or geometry. [0071] Figures 19A-C are a front view and two cross-sectional views of another example respirator having a cartridge with a stack of polymer layers as described herein. This respirator has a three main component construction where the main body that engages with the face is a thin injection molded part of appropriate size and shape to provide the best chance of accommodating a variety of face geometries, with a co-injected medical grade silicone rim to provide some compliance and conformal effect to improve sealing of the respirator and reducing airflow from around the perimeter of the respirator. [0072] To create a mask assembly, the face frame serves as a mounting platform for the pathogen substrate, with a perforated cone mounted to the assembly to the complete mask. For the active UV LED version of the mask, the pathogen substrate can serve as the mounting platform for the LEDs and any related components. [0073] Figures 20A and 20B are front views of an example respirator having a polymer strap attached thereto. Strap design can be important to make sure the respirator is secured well and retained tight to the face while accommodating many user variables and remain washable or easily sterilized. The drawing below illustrates one option for a strap that is a strip of polymer that has features cut to provide the ability to stretch or elongate, with the feature region laminated with medical grade silicone to provide the elastic effect and prevent the thin features from being damaged. There may also be need for the strap ends at the mask interface to be adjustable, otherwise the basic strap can be fusion bonded to the face frame. [0074] Figures 21A-C are a front view, an enlarged view, and a cross-sectional view of an example respirator 2100 having relief cuts 2102 defined therein. In an effort to improve the fit to the user’s face, the perimeter of the polymer main body of the respirator 2100 can be patterned with relief cuts 2102 that allow for some level of compliance or form fitting. Silicone (e.g., a medical grade thin silicone layer) can be disposed over the relief cuts 2102 to contain the relieved polymer regions as well as provide the ability to stretch and conform to the user’s facial structure and provide some level of sealing to drive airflow through the desired regions of the respirator 2100. Although only a single relief cut 2102 is shown in Figure 21A it should be understood that a plurality of relief cuts 2102 can be defined in the perimeter of the main body as desired. [0075] Figures 22A and 22B are a front view and a cross-sectional view of an example off-the- shelf respirator 2200 having a cartridge formed of a plurality of polymer layers as described herein attached thereto. In an example, a cartridge as described herein can be configured to attached to an off-the-shelf respirator to enhance the filtering ability of the respirator and/or add additional functionality to the respirator, such as antiviral properties. A thin pathogen cartridge 2202 that is either conformal or formed to shape and attached to the inner surface of the off-the-shelf respirator 2200. Hooks, or prongs or pins 2204 can be used to affix the pathogen shield to the fabric of the existing mask with the intent of retention during use but also removal and placement on another mask after cleaning and sanitation. In an effort to keep complexity and cost down, a simple torture path of only a few layers in the cartridge 2202 is likely adequate to improve the pathogen disabling effect while the existing mask provides a level of filtering. A thin capture layer on the outer surfaces of the pathogen layers can prevent direct contact with the silver plating. [0076] Figures 23A-C are front views and a cross-sectional view of an example respirator 2300 having a strap with embedded circuits therein. A significant advantage is the ability to embed and power Ultraviolet LEDs within the mask structure. Studies have shown that 2mJ/cm- squared of 22 nm wavelength UV light is effective in disabling viruses in airborne form. In an example, this respirator 2300 is configured to provide a UV source and UV power supply within the structure of the mask and the strap affixing the mask to the head and face such that during use the user’s airstream is exposed to the UV pathogen disabling effects. The mask can be constructed with the UV feature as a stand-alone version or combined with the anti-pathogen silver bearing matrix. [0077] Respirator 2300 includes an embedded solid state or thin film polymer batteries within the mask strap, as well as potentially any power management or sensor devices as needed. Embedded circuits extend to an interconnect point to the pathogen substrate which can be a stud bump, or solder joint, or connector etc. In some cases, the strap may be separable from the mask, while in some cases it may be desirable to permanently bond the strap to the mask. In some cases, it may be desirable to replace the batteries, and in some cases the batteries are to be embedded with appropriate charging circuitry and electronics to accommodate wireless charging, or direct interconnect to a charging mechanism either while connected to the mask or discretely when detached from the mask. This electronic function can be used when UV LEDs are contained within the mask structure, or there may be of benefit to provide current or charge to the pathogen matrix during use or during sterilization to increase the efficacy of disabling pathogens. [0078] The above example relies upon the premise that UV LEDs are located within the air chamber, likely mounted to the pathogen substrate or potentially the interior of the mask itself. It is important to position the LEDs in proper direction and in sufficient quantity such that the light shroud or effective impact are covers the majority of the effective region within the chamber and path of the airflow. In an example, the light shroud can be contained and restricted to the air chamber as much as possible as to prevent UV leakage beyond the desired chamber whether exposing the wearer or the aera outside of the immediate mask areas. From an electronics efficiency point of view, the LEDs and power management functions can be disposed as close to the power source as possible. The precision embedded circuits do provide a very low resistance path, and the active LEDs within the chamber will likely mounted in a way that can help manage any thermal or heat generation issues. [0079] Figures 24A and 24B are cross-sectional views of yet another example respirator 2400 having batteries embedded in the straps and light pipes for delivering the light to the air chamber. This is an alternative or addition to the air chamber mounting of the LEDs. Here the LEDs are embedded within the strap structure and create a light pipe that transmits UV light into the air chamber at proper locations with the light transmission aimed at the appropriate air chamber areas. The battery power is embedded within the strap architecture, and also embedding the UV LEDs within the strap in such a way that light pipes are aligned to the LED emitter and transmit the UV light through the strap and aligned to the air chamber to saturate the cavity with UV light to disable pathogens within the airstream. [0080] Additional information regarding methods for embedding circuits, other components, and defining features with the polymer are disclosed in PCT Patent Application No. PCT/US2020/060631, filed on Nov.15, 2020 and entitled “LIQUID CRYSTAL POLYMER EMBEDDED MICROELECTRONICS DEVICE”. [0081] Figures 25A-C are front views and cross-sectional views of a respirator 2500 that combines the filter effects of a traditional N95 or KN95 type facial mask and the benefits of the stacked polymer layers as described herein. In this example, a combination mask is shown where a construction consists of a face frame with a sealing gasket flange, and an end cone that provides structural support for a N95 type filter material such as blown fiber matting, with a stacked polymer layer defining tortuous air passages mounted near the interface of the face frame and the end cone. [0082] The benefits of the stacked polymer concepts over conventional protective facial masks can include: 1) The polymer construction creates a protective facial mask that can be cleaned, sterilized, and reused many times.2) The polymer construction can be processed with plasma deposited monomer to enhance non-wetting properties.3) The polymer construction can be fabricated in a simple passive form as a filter similar to conventional masks.4) The polymer construction can be enhanced to provide active pathogen attacking features and function which is absent from conventional facial masks.5) A metalized network can be connected to current for sterilization or thermal or electrical treatment to enhance pathogen destruction.6) The polymer construction can be fabricated to add electronic function to enhance the pathogen attacking effectiveness, as well as embedded sensors to monitor the environment or contact with pathogens, wireless communication to report conditions and data, power management and charging functions to facilitate solid state battery power. [0083] Conventional N95 respirators are typically constructed of layers of filtration materials commonly referred to as non-woven, or melt blown non-woven. This material as the name implies, relies on relatively random yet massive amounts of polymer filaments that when meshed together create a filtration effect of spider web like structures intended to capture small particles as they pass through the matrix. To enhance the filtration efficiency, the material is typically statically charged such that when particles enter the matrix the static electricity improves the capture percentage. [0084] A key aspect of the N95 respirator products is they must be fit properly to the face in order to achieve desired target filtration. If not properly fit, the airflow tends to escape and enter around the perimeter of the respirator which defeats the filtration principle with unfiltered air entering and exiting. A requirement for proper fitting is adequate training of the user to properly fit the respirator to their particular facial structure to avoid leakage. In general, this training is done on a yearly basis with the use of a fit check tester that measures the pressure drop and leakage potentials. This test is not done every time the user wears a respirator, and the effectiveness relies upon the user’s skill and diligence to achieve proper fit to maximize filtration. [0085] The harsh reality of the this fit to face requirement is the material has some compliance but must be held to the face with significant pressure which essentially relies partially on the compliance of the face itself. In some cases, a silicone rim is over-molded to add some compliance. The retention mechanism that holds the respirator against the face is typically behind the ear or behind the head loop elastic straps that are attached to the respirator at roughly the 2 and 4 and 8 and 10 o’clock positions. The requirement for proper no leak fitting makes the respirator difficult to wear comfortably for long periods of time and often results in skin issues at the interface locations. [0086] The nature of the filtration mechanism also significantly increases airflow restriction which is a balancing act between particle capture and ease of breathing. In some cases, one way exit valves are used to relieve the exhalation pressure to ease breathing but these structures do not filter the outgoing airflow and have been avoided. These respirators are also intended to be a one-time use and discarded, with a fresh replacement at each sequential use. The nature of the filtration material capturing particles, retaining moisture and contamination also make the respirators impossible to clean and very difficult to sanitize. Use of a contaminated respirator can dramatically increase the risk of infection to the user or those nearby. Another short coming is the respirator obscures and covers the users face while also muffling conversation, understanding and facial expression. [0087] Another shortcoming of the filtration principle is a significant percentage of the exhaled air is rebreathed during the subsequent inhalation. If the user is exhaling pathogens, then they will continually infect themselves by rebreathing expelled air as well as wearing a contaminated respirator. [0088] Although N95 respirators are very difficult to wear, must be fit properly to provide proper protection, and are impossible to clean they are the recommended best protection against airborne pathogens and do provide some protection from surface pathogen transmission by keeping the user from touching the face. [0089] Figures 26A-D are perspective views of an example main body 2602 to which a cartridge can be removably secured. The main body 2602 and cartridge are configured such that the cartridge can be removably secured to the main body. That is, the cartridge can be secured to the main body 2602 for use and, after some length of use corresponding to a lifetime of the cartridge, the cartridge can be removed from the main body 2602 and cleaned or discarded. A new or cleaned cartridge can then be re-secured to the main body 2602 to continue using the respirator. The main body can be configured to block air flow between an internal cavity and the external environment, except for where the cartridge is secured thereto. The main body 2602 can define one or more apertures 2604 where the cartridge is attached thereby directing the airflow between the internal cavity and the external environment through the cartridge. In this example, the apertures 2604 are disposed proximate a mouth of the user, however, in other example, apertures can be disposed in other areas instead of or in addition to apertures 2604. The main body 2602 can define a slot 2606 configured to accept and mate with a T stub on a cartridge as described below. [0090] The main body 2602 can also define 2608 one or more locations for connection of one or more straps for securing the body 2602 onto a head of a user. The main body 2602 can also define an edge region proximate a face of the user having a profile configured to have a silicone or other compliant material disposed thereon for compliant and comfortable contact between the main body 2602 and a user’s face. [0091] Such a design with a cartridge secured thereto provides a respirator that has a reusable base structure (main body 2602) that can be easily cleaned and sanitized hundreds if not thousands of times. The respirator can be easy fit to face with comfortable sealing and no skin irritation issues. The respirator can provide self-adjustment retention to provide proper seal with minimal pressure against the face. The respirator 2600 can provide targeted filtration to optimize airflow and comply with N95 rating standards. The respirator can have easily replaceable filtration via the cartridge with multiple cartridge options considering environment and protective needs. The main body 2602 of the respirator can be composed of an optically clear material to allow for visual viewing of the wearers face and expressions. The respirator 2600 can add pathogen destruction and disablement beyond simple filtration. [0092] Most consumer product enhancements claim anti-microbial properties with coatings, nano-particles, or metallic filaments or threads incorporated into the fabric. These methods do have some potential benefits in destroying microbes and bacteria with limited effect on viruses and more lethal pathogens. There are no respirator products that add anti-pathogen function with commercially available products focused on filtration standards. [0093] The respirator can provide dramatic improvements to the user experience of wearing a respirator while adding a unique technology approach to pathogen destruction beyond simple filtration. The respirator incorporates a generally planar surface or surfaces on the cartridge that bear anti-pathogen metallization that is strategically located within the airstream of inhale or exhale or both. This planar member can be described as an electrical circuit like member, as it can be a passive structure that simply bears metallization or coatings that disable or destroy a virus or pathogen that encounters the surface, or it can be an active circuit member that provides a platform for electrification of circuits or powering devices. [0094] The anti-pathogen circuit or anti-pathogen surface placed within the airflow path in some fashion has significant advantages over the methods used to incorporate particles, threads, or coatings within a cloth consumer face mask. Those methods have a relatively small density of anti-microbial or antiviral material relative to the actual material content of the mask and corresponding airflow volume. In other words, the vast majority of the airflow and airborne pathogens pass through the untreated areas of the fabric. The use of a surface bearing anti- pathogen properties significantly increases the probability of any airborne pathogen encountering the surface and remaining in a disabled state no longer able to infect or replicate. Since the airborne pathogen are essentially caried by moisture droplets large and small, the surface can be enhanced to promote pathogen capture and prolong the duration of direct contact with the anti-pathogen measures. [0095] The main body 2602 can be constructed from a wide variety of polymer choices that can be molded, shaped or thermo-formed such as Liquid Crystal Polymer, Polycarbonate, PEI, Acrylic, Silicone, Neoprene etc. The physical properties of the base frame can vary widely depending on desired features and functions such as rigidity, weight, transparency, flexibility, etc. [0096] In one example, main body 2602 has a construction based upon Polycarbonate or Acrylic polymers that provide mechanical infrastructure to incorporate multiple components and features while being optically clear to allow for the users face and facial expressions to be viewed while conventional respirators block the view of the face. These polymers will typically yield a rigid structure but depending on the design the respirator could be made flexible or partially flexible for reasons such as flat storage or distribution. [0097] From a product acceptance standpoint, the general shape and appearance of the main body 2602 and overall respirator is generally curvilinear and in basic terms serves as the structure that holds and presents the filtration and anti-pathogen structure at the proper location within the airflow path. The structure also serves as the skeleton for arranging and attaching various components that provide features such as facial sealing, respirator retention on the user’s head, filter replacement, electronics integration, filter attachment etc. [0098] Figures 27A and 27B are exploded views of an example cartridge 2700 for use in any of the cartridge respirators described herein, including with main body 2602. As shown in Figure 27A, the cartridge 2700 includes a molded support member 2702 that defines one or more inlet apertures 2704 and one or more outlet apertures 2706. In this example, the support member 2702 defines an outer ring 2708 and an inner ring 2710. The one or more inlet apertures 2704 are defined between the outer ring 2708 and the inner ring 2710. The one or more outlet apertures 2706 are defined inside the inner ring 2710. The inner ring 2710 therefore is also referred to herein as an exhaust valve ring. The support member 2702 defines a shallow tube feature that extends from the inner ring 2710 and functions as the exhaust port. This exhaust port is located in the center of the support member 2702 such that it is positioned immediately in front of a user’s mouth while being worn. Accordingly, when a user exhales, the general direction of the exhale does not have to change, ensuring there is a high force on the exhaust valve and a high level of the exhaling breath leaves the respirator quickly. The cartridge 2700 includes an exhaust valve 2712 that is disposed in the exhaust port and restricts air coming into the interior cavity of the respirator while allowing air to easily exit from the interior cavity of the respirator. In this example, the exhaust valve 2712 is a silicone valve having a shape that covers substantially all of the one or more outlet apertures 2706. The exhaust valve 2712 is disposed on the outward side of the one or more outlet apertures 2706 and extends all the way over the apertures 2706 to the structures on all sides of the apertures, such as to a valve stop shelf defined on the outside edges of the apertures and the internal spokes extending from the valve stop shelf to an internal hub of the support member 2702. In an example, the outward facing surfaces of the valve stop shelf and internal spokes are at a common position such that the silicon valve when forced inward during inhale contacts the valve stop shelf and internal spokes at the same time and therefore seals the outlet apertures 2706. Conversely, a cap 2718 that covers the silicone valve in the exhaust port provides a cavity on the outward side of the silicone valve allowing the silicone valve to flex and allow air flowing out of the outlet apertures 2706 to exit the respirator. The exhaust port has a post is located in the center to locate and affix the valve 2712. The valve 2712 itself is a thin molded silicon sheet with a hole in the center for the post, and some raised ribs to help bias the valve against the valve stop shelf which is interior to the exhaust port ring. [0099] A filter material 2714, such as a N95 type filter material, is disposed over the inlet apertures 2704 to filter incoming air entering the respirator. In this example, the filter material 2714 has a generally annular shape and extends from the inner ring 2710 to the outer ring 2708. The filter material 2714 is cut to a diameter shape, with a hole in the center to clear the exhaust port tube. The material is heat sealed to a shelf that is exterior to the exhaust port as well as the outer perimeter of the ring to seal and prevent leakage. A molded cap 2718 is included that slips onto the outer diameter of the exhaust port ring 2710, with slots around the perimeter wall that allow for the exhaust air to exit freely. The interior of the support ring is shown with 4 thin webs to maximize air flow area and provide some theoretical compliance around the ring when loaded against the gasket-mask face seal. [0100] The cartridge also defines a cartridge securing member that is configured to removably secure the cartridge to the main body. In an example, the cartridge securing member is a physical structure that removably interlocks with a corresponding structure on the main body of the mask. In other examples, other cartridge securing members can be used, such as an adhesive, magnet, or Velcro type feature. In this example, the mask mating member is a ‘T’ stub feature 2416 extending therefrom that mates with a corresponding female slot on the main body. The T stub 2416 and corresponding female feature are configured such that the cartridge can be removably secured to the main body by inserting a T stub feature into the female feature and rotating the cartridge relative to the main body to lock the taps of the T stub into the female feature. A gasket is located around the perimeter of the support ring to seal against the main body surface during the twist action that is intended to pull the ring towards the surface of the main body. [0101] Figure 28 is another example of a main body 2800 of a respirator having a fit tester port 2802. A relationship has been established with TSI who is the world supplier of test instruments that are used to validate the N95 particle filtration efficacy of the filter materials, as well as an instrument called a fit tester. The fit tester is used to validate the fit and seal of the respirator while in place on the user’s face. This is a cumbersome process and is rarely used each and every time a respirator to put on which defeats much of the effectiveness with air leakage around the edges. Accordingly, a fit test port can be included such that the user can fit the respirator and easily test the effectiveness of the fit and seal with a fit tester, such as the one manufactured by TSI. [0102] Figures 29A and 29B are a front view and a cross-sectional view of another example of a cartridge 2900. This is similar to cartridge 2700 except the filter material 2904 is disposed internally to the support member 2902. The filter material 2904 is affixed with an O ring style gasket 2906 that secures the filter material in place by pinching the material 2904 into a groove 2908 defined in the support member 2902. The gasket 2906 also provides the seal to the main body of the respirator. This example can provide touch points on the support member 2902 for the user to use during securing to the main body. These touch points allow the user to twist against the ribs rather than touching and potentially contaminating the filter material before use. [0103] Figures 30A and 30B are cross-sectional views of an example of a cloth stack 3000 that can be used as filter material on a cartridge as described herein. The cloth stack 3000 includes a polyester film retention ring 3002 and a layer of filter material 3004 (e.g., a GSM 25 material) disposed underneath the polyester film. A spun bond glue 3006 is disposed under the filter material 3004 and a plurality of stubs 3008 extending from a support member of a cartridge are used to secure the retention ring 3002 and filter material 3004 onto the support member. [0104] Figure 31 is a cross-sectional view of a filtering portion that can be used in a cartridge or in a main body of a respirator. The filtering portion can include a filter batting layer 3102 that functions as a filter material and has a layer 3104, 3106 of polymer with copper thereon on both sides of the batting layer. The polymer-copper layers 3104, 3106 can be secured to the batting layer 3102 and can define a plurality of spaces for air to flow therethrough. In an example, the spaces in polymer-copper layer 3104 on one side can be alternated with the spaces of the polymer-copper layer 3106 on the other side such that the air is directed into contact with one or both of the layers 3104, 3106 as it passes through the cartridge. A fine mesh layers 3108, 3110 can be disposed on the external sides of the polymer-copper layers 3104, 3106. [0105] Figures 32A-C are front views of example components for the filtering portion of Figure 31. Figure 32A is an example support member to which the filtering portion can be attached. The support member includes a plurality of apertures that function as both inlet and outlet apertures for the respirator. The support member can include a member to removably secure the cartridge to a main body, such as T stub located in a center thereof. In an example, the support member has a circular shape with an outer ring, an inner hub, and spokes extending from the outer ring to the inner hub. The spaces defined between the outer ring, inner ring, and spokes comprise the inlet/outlet apertures are described herein. Figures 32B and 32C are front views of example polymer-copper layers showing the relative orientation of each such that air flow is directed past each of them. [0106] For the copper polyimide layers, the idea is to have a cut shape that provides copper both sides with surface areas that drive airflow against the copper relative to the webs in the molded cone on the mask. The drawing below is very crude to illustrate the principle, with the left image being the inner layer corresponding to the web configuration on the molded mask and the right image is a corresponding rotation in the pattern to try and put copper in the way of the air flow as it passes through the batting material into the user inhale and be in the way of exhale airflow as much as possible considering the relief valves. The spacer gap created by the batting layer is hoped to provide enough room for air to flow through the batting filter material and come into contact with the outer and inner copper layers. [0107] Figure 33 is a cross-sectional view of another example filtering portion that can be used in a cartridge or in a main body of a respirator. The filtering portion includes a filter layer 3302. In an example, the filter layer 3302 is composed of cotton. The filtering portion includes a ring spacer layer 3304 with a fine mesh layer between the ring spacer layer 3304 and the filter layer 3302. The filtering portion also includes a pinwheel spacer layer 3306 and a copper flex layer 3308 disposed between the ring spacer layer 3304 and the pinwheel spacer layer 3306. [0108] Figure 34A is a front view of the copper flex layer 3308 and Figure 34B is a front view of the pinwheel spacer layer 3306. Another fine mesh layer can be disposed on the outside of the cotton filter layer 3302 and on the outside of the pinwheel spacer 3306. Figure 34C is a side cross-sectional view of the filter portion of Figure 33 illustrating its concave shape to provide natural space for a user’s face. [0109] The copper flex layer 3308 can be composed of a polymer layer having a copper layer on both sides of the polymer layer. The copper flex layer 3308 defines a plurality of flaps that are configured to flex slightly in response to air flow into and/or out of the respirator. The flex in the flaps allows for air to more easily flow through the copper flex layer 3308. The flex, however, is kept low (e.g., less than 30 degrees from normal) such that the air flows past the angled flaps as it travels through the copper-flex layer 3308. In an example, the one or more flaps are configured to flex both inward and outward to allow air to flow both inward and outward past the flaps. In another example, a first one or more flaps are configured to flex inward for incoming air and a second one or more flaps are configured to flex outward for outgoing air. [0110] The copper flex layer 3308 is configured to contact the pinwheel spacer 3306 shown in Figure 34B. The pinwheel spacer 3302 includes an outer ring that contacts an outer edge of a first plurality of larger flaps 3310 defined in the copper flex layer 3308. The pinwheel spacer 3302 also includes a plurality of spokes that extend from the outer ring and contact the larger flaps 3310 along respective sides thereof. The contact between the pinwheel spacer and the larger flaps 3310 prevents the larger flaps 3310 from flexing towards the pinwheel spacer 3306. In an example, the copper flex layer 3308 is secured to the pinwheel spacer 3306 proximate a center thereof. The ring spacer 3304 has an outer ring without spokes. The outer ring is disposed outward of the larger flaps 3310, such that the larger flaps 3310 can flex into the large aperture formed by inside the outer ring. In this way, the filtering portion enables the larger flaps 3310 to flex one way and restricts them from flexing the other way. [0111] The copper flex layer 3308 also defines a plurality of smaller flaps 3312. In this example the smaller flaps 3312 are defined within the larger flaps 3310. The pinwheel spacer 3306 such that it does not contact the smaller flaps 3312, thereby allowing the smaller flaps to flex towards the pinwheel spacer. In this way, the larger flaps 3310 are configured to flex one direction (e.g., outward) and the smaller flaps 3312 are configured to flex in the other direction (e.g., inward). Advantageously, by embedding the smaller flaps 3312 in the larger flaps 3310, the surface area of surface area of the copper flex layer 3308 is well utilized. This is because air is forced against a large portion of the first side of the copper flex layer 3308 when the larger flaps 3310 flex in the first direction. Additionally, air is forced past a large portion of the second side of the copper flex layer 3308, reverse of the first side when the smaller flaps 3312 flex in the second direction. In other examples, the copper flex layer can have other antiviral materials in addition to or instead of copper, such as silver and/or zinc. In yet other examples, the copper flex layer 3308 can be composed solely of a metal such as copper, silver, or zinc (e.g., at least 90%, 96%, or 99.9% pure copper, silver, and/or zinc). [0112] Accordingly, the copper flex layer 3308 uses both sides as an anti-pathogen layer as well as a pseudo exhaust valve contained within the filter. In an example, the fine mesh layer on the outside of the batting layer 3302 is a thin cotton outer layer to contain any filter layer fibers and provide a clean outer surface. In an example, the batting layer 3304 is a cotton batting filter layer or alternate N95 type spun polyester non-woven filter material. In an example, fine mesh cotton between the ring spacer 3306 and the batting layer 3304 contains the filter batting material and keeps the batting filter material spaced from the copper flex layer 3308 to allow space for the flaps of the copper flex layer 308 to flex. In an example, the copper flex layer 3308 is composed of a polymer, such as Kapton, polyester, polyolefin, LC with copper on both sides. In an example, the slots defining the flaps in the copper flex layer 3308 are 1 mm across. In an example, the pinwheel spacer layer 3306 matches the webs on the main body and allows the major (larger) flaps 3310 of the flex layer 3308 to flex outward during exhale and allows the interior (smaller) arrowhead shaped flex flaps 3312 to flex inward during inhale. The pinwheel spacer 3306 can be a molded part to provide contour support and keep the cotton batting filter layer from bunching or trying to impede the flex features from moving. In an example, the fine mesh layer on the outside of the pinwheel spacer 3306 can enclose the copper flex features. In an example, a ring of PSA will go around the periphery of the filter about 5 mm wide and can be placed on the pinwheel spacer 3306 if the cotton layer does not extend all the way out to the edge. [0113] As described above, the major flex flaps 3310 of the copper flex layer 3306 resides on the webs of the pinwheel spacer 3306 which will prevent inward flexure during inhale, while the spacer ring 3304 provides space for the major flaps 3310 to flex during exhale. The interior flex flaps 3312 can flex inward during inhale and will likely be subordinate during exhale. The goal is to have the airstream flow through the filter batting layer inhale and exhale while driving the airflow in contact with the exposed copper as much as possible without restricting too much airflow without large perforations. The goal is also to provide the copper pathogen effect in a single circuit layer. Another copper circuit layer (e.g., copper flex layer 3308) can be added to increase the anti-pathogen effect. [0114] Although a specific geometry for the flaps of the copper flex layer 3308 is shown and described, other geometries having flexible flaps can be used. [0115] Figures 35A-C are a front view, an enlarged view, and a cross-sectional view of another example copper flex layer for use in the filtering portion described with respect to Figures 33 and 34. In this example, the copper-flex layer is similar to copper-flex layer 3308, except the copper-flex layer shown in Figures 35A-C has a plurality grooves 3502 defined in the copper surfaces 3504 of the copper-flex layer. The copper layers 3504 are on both sides of a layer of polymer 3506 as described above with respect to copper flex layer 3308. The surfaces can have copper (other antiviral material as described herein) across the top, sides, and bottom of grooves. That is, all exposed surfaces in the area having the grooves can be composed of copper. The grooves increase the surface area of the copper and provide roughness which can aid causing the pathogens in the air to come into contact with the surface. Although only a single groove is shown in Figure 35B it should be understood that multiple grooves can be included. In an example, parallel grooves are included (e.g., on substantially all) of both exposed copper surfaces of the copper flex layer. In an example, the grooves are less than 100 microns deep, such as 10 microns deep in an 18 micron thick copper layer. The grooves can be less than 500 microns wide, or less than 250 microns wide or less than 100 microns wide. In an example, the grooves are 75 microns wide. In an example, adjacent grooves are less than 500 microns apart, less than 250 microns apart, less than 100 microns apart. In an example, the grooves are less than 75 microns apart. Other dimensions are also possible for the grooves. [0116] Figures 36A-F are other example respirators having cartridges that can be secured thereto. The cartridges can include any of the filtering and antiviral aspects described herein. [0117] In an example, the antiviral material described in any of the examples herein can include copper, silver, zinc or a combination thereof. In an example, the antiviral material is zinc plus copper, wherein there is a base copper layer with a nickel barrier and zinc over the nickel. Portions of the copper are exposed alongside exposed zinc creating an oxidation reaction between the two substances in the presence of moisture (e.g., water droplets). The nickel is used to plate the zinc on the copper in a way that reduces attach of the copper by the zinc. In another example, a base zinc layer is used with copper added to the zinc and having exposed copper next to exposed zinc. [0118] In some examples, a saline can be applied over the exposed copper and zinc and then dried so that dried salts reside on the exposed copper and zinc surfaces. While the surfaces remain dry, the oxidation reaction is paused, and the salt remains dried. As the surface is exposed to moisture (e.g., a user’s breath) the salt dissolves and jump starts the metal free ion exchange during oxidation creating a mild voltage self-generating battery effect. This can be highly effective at disabling viruses. The saline adds sodium and chloride ions that drive the oxidation corrosion which is the basic chemical reaction that destroys the virus’s ability to replicate.

Claims

CLAIMS What is claimed is: 1. A respirator comprising: a main body having a geometry configured to fit on a human face and cover the human’s mouth and nose, the main body defining an interior cavity between the main body and the human’s face; one or more apertures in the main body providing a passage for air to flow between the interior cavity and an external environment, wherein the main body is configured such that air flow is blocked between the interior cavity and the external environment, except for through the one or more apertures; and a cartridge removably secured to the main body, the cartridge covering the one or more apertures and having at least one of a pathogen filter or an antiviral material that is disposed such that the air flowing through the one or more apertures passes through the filter or past the antiviral material as it flows between the interior cavity and an external environment.

2. The respirator of claim 1, wherein the one or more apertures are disposed on the main body such that the one or more apertures are in front of a human’s mouth while the respirator is being worn.

3. The respirator of claim 1, wherein the main body defines a cartridge securing member configured such that the cartridge is held in place on the main body by the cartridge securing member.

4. The respirator of claim 1, wherein the main body defines a cartridge mating component and the cartridge defines a mask mating component, the mask mating component configured to mate with the cartridge mating component to removably secure the cartridge to the main body, wherein the cartridge mating component and the mask mating component are configured to allow the cartridge to be removed from the mask.

5. The respirator of claim 4, wherein the cartridge mating component and the mask mating component are configured such that the cartridge can be secured to and removed from the mask by hand without any tools.

6. The respirator of claim 4, wherein the cartridge mating component and the mask mating component include male and female interlocking members.

7. The respirator of claim 6, wherein the male and female interlocking members are configured such that the male member can be inserted into the female member and the cartridge can be rotated relative to the main body to lock the male member and the female member together and thereby secure the cartridge to the main body.

8. The respirator of claim 7, wherein the male member is disposed on the cartridge and the female member is defined in the main body.

9. The respirator of claim 1, wherein the pathogen filter material meets the N95 standard for pathogen filtration in the United States of America.

10. The respirator of claim 1, wherein the antiviral material includes one or more of copper, silver, and/or zinc.

11. The respirator of claim 1, wherein the main body is rigid.

12. The respirator of claim 1, wherein the main body is see-through.

13. A respirator comprising: a main body configured to be worn on a human face, the main body having a first side and a second side, the main body including: one or more polymer layers defining a plurality of apertures, the plurality of apertures providing passages for air to flow between the first side and the second side of the main body; and an antiviral material disposed on the one or more polymer layers proximate the plurality of apertures.

14. The respirator of claim 13, wherein the antiviral material is disposed on an interior surface of the plurality of apertures.

15. The respirator of claim 13, wherein the one or more polymer layers include a plurality of polymer layers stacked on one another, each polymer layer defining a plurality of apertures, wherein the polymer layers are disposed relative to one another such that continuous passages are formed by the plurality of apertures in respective layers from the first side to the second side of the main body, wherein the plurality of apertures in adjacent layers are misaligned such that as the air flowing through the continuous passages passes between adjacent polymer layers, the misaligned apertures force the air to weave through the polymer layers.

16. The respirator of claim 15, wherein the antiviral material is disposed on an interior surface of the plurality of apertures.

17. The respirator of claim 15, wherein the plurality of apertures of each layer having an aspect ratio between 2:1 and 1:2, wherein the aspect ratio is a ratio of the thickness of the polymer layer to the distance across the aperture.

18. The respirator of claim 13, wherein the antiviral agent is one or more of copper or silver plating on an interior surface of the plurality of apertures.

19. The respirator of claim 18, comprising electrical traces electrically coupling the one or more of copper or silver plating in the plurality of apertures together, such that an electric charge can be applied to the plurality of apertures.

20. The respirator of claim 13, wherein the antiviral agent is one of a copper or silver layer on a surface of the one or more polymer layers.

21. The respirator of claim 13, wherein the one or more polymer layers form the main body, which has a geometry configured to fit on a human face and cover the human’s mouth and nose, the main body defining an interior cavity between the main body and the human’s face.

22. The respirator of claim 13, wherein the plurality of apertures include a plurality of flaps defined in the one or more polymer layers, the plurality of flaps bent with respect to the one or more polymer layers to form respective apertures in the polymer layers.

23. The respirator of claim 22, wherein at least a portion of a surface of the plurality of flaps is composed of the antiviral material.

24. The respirator of claim 23, wherein the plurality of flaps are configured to be stationary during breathing while the mask is being worn.

25. The respirator of claim 23, wherein the plurality of flaps are configured to flex at least one of inward or outward in response to force on the flaps caused by air flow during at least one of inhaling or exhaling while the mask is being worn.