Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled larger size and smaller size continuous monocomponent polymeric fibers of the same polymeric composition. Rows of pleats are formed in the nonwoven web, and the pleated web is cut to a desired size and shape to provide a filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers or other reinforcing measures in the filter media layer.

Abstract: Reinforced filter media are prepared by adhering discrete, non-intersecting strands of thermoplastic or thermoset materials to the filter media web. The filter media may be a fabric, a nonwoven web or a filtering foam. The reinforced filter media can be used to prepare respirators, including flat-fold respirators or molded respirators.

Abstract: Articles comprise: a nonwoven fiber web and one or more strips bonded to the nonwoven fiber web. The strips comprise a shape-memory polymer that has a strained temporary shape and an intrinsic shape. If heated at or above a transition temperature, the strip at least partially converts from the strained temporary shape to the intrinsic shape, thereby causing at least one of folding, cupping, or puckering of the non-woven fiber web. Methods of heating the articles to provide folded, cupped, and/or puckered articles are also disclosed.

Abstract: A dust collection device for a sanding tool comprising a bag having a sidewall and a coupler attached to the bag. The sidewall comprising a first filter layer, a second filter layer, and an outer support layer. The first filter layer comprising a plurality of fibrillated electrostatically charged electret fibers forming a nonwoven web; the first filter layer having a total pressure drop between about 0.1 to about 4.0 mm H2O, and the first filter layer having a total basis weight between about 50 to about 450 gram/m2. The second filter layer comprising a melt blown microfiber nonwoven web; the second filter layer having a total pressure drop between about between about 5.5 to about 20.0 mm H2O, and the second filter layer having a total basis weight between about 15 to about 75 grams/m2.

Abstract: A flat-fold respirator is made from a stiff filtration panel joined to the remainder of the respirator through at least one line of demarcation. The panel contains a porous monocomponent monolayer nonwoven web that contains charged intermingled continuous monocomponent polymeric fibers of the same polymeric composition and that has sufficient basis weight or inter-fiber bonding so that the web exhibits a Gurley Stiffness greater than 200 mg and the respirator exhibits less than 20 mm H2O pressure drop. The respirator may be formed without requiring additional stiffening layers, bicomponent fibers, or other reinforcement and can be flat-folded for storage. Scrap from the manufacturing process may be recycled to make additional stiff filtration panel web.

Abstract: Shaped filtration articles are made from a monocomponent nonwoven web formed by flowing first and second fiber-forming materials of the same polymeric composition through first and second die cavities in respective fluid communication with first and second sets of orifices in a meltblowing die tip. The first fiber-forming material flows at a lesser flow rate or viscosity through the first die cavity and first set of orifices to form a set of smaller size filaments and the second fiber-forming material flows at a greater flow rate or viscosity through the second die cavity and second set of orifices to form a set of larger size filaments. The collected nonwoven web contains a meltblown bimodal mass fraction/fiber size mixture of intermingled continuous microfibers and larger size fibers of the same polymeric composition.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web of continuous monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that are bonded to form a coherent and handleable web having a Gurley Stiffness of at least 100 mg and which further may be softened while retaining orientation and fiber structure. Rows of pleats are formed in the nonwoven web, and the web is cut to a desired size and shape to provide a pleated filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers, adhesive or other reinforcement in the filter media layer.

Abstract: A porous nonwoven web and method of making are disclosed, wherein the web contains meltblown fibers and staple fibers. The meltblown fibers may be present as a bimodal mixture of microfibers and mesofibers, and comprise an intermingled mixture with staple fibers further intermingled therein.

Abstract: A molded respirator and method of making are disclosed, wherein the molded respirator is made from a porous nonwoven web containing meltblown fibers and staple fibers. The meltblown fibers may be present as a bimodal mixture of microfibers and mesofibers, and comprise an intermingled mixture with staple fibers further intermingled therein. The molded respirator may also contain at least one secondary filtration layer.

Abstract: A molded respirator is made from a monocomponent monolayer nonwoven web of continuous charged monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that have been bonded to form a coherent and handleable web which further may be softened while retaining orientation and fiber structure. The respirator is a cup-shaped porous monocomponent monolayer matrix whose matrix fibers are bonded to one another at at least some points of fiber intersection. The matrix has a King Stiffness greater than 1 N. The respirator may be formed without requiring stiffening layers, bicomponent fibers, or other reinforcement in the filter media layer.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web of continuous monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that are bonded to form a coherent and handleable web having a Gurley Stiffness of at least 100 mg and which further may be softened while retaining orientation and fiber structure. Rows of pleats are formed in the nonwoven web, and the web is cut to a desired size and shape to provide a pleated filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers, adhesive or other reinforcement in the filter media layer.

Abstract: A molded respirator is made from a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled continuous monocomponent polymeric microfibers and larger size fibers of the same polymeric composition. The respirator is a cup-shaped porous monocomponent monolayer matrix whose matrix fibers are bonded to one another at least some points of fiber intersection. The matrix has a King Stiffness greater than 1 N. The respirator may be formed without requiring stiffening layers, bicomponent fibers, or other reinforcement in the filter media layer.

Abstract: A molded respirator is made from a monocomponent monolayer nonwoven web of continuous charged monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that have been bonded to form a coherent and handleable web which further may be softened while retaining orientation and fiber structure. The respirator is a cup-shaped porous monocomponent monolayer matrix whose matrix fibers are bonded to one another at least some points of fiber intersection. The matrix has a King Stiffness greater than 1 N. The respirator may be formed without requiring stiffening layers, bicomponent fibers, or other reinforcement in the filter media layer.

Abstract: A porous monocomponent nonwoven web contains a bimodal mass fraction/fiber size mixture of intermingled continuous microfibers and larger size fibers of the same polymeric composition. There are at least five times as many microfibers as larger size fibers, and a histogram of the mass fraction of fibers vs. fiber size exhibits a larger size fiber mode greater than 10 ?m. The web may be made by flowing fiber-forming material through a die cavity having larger size orifices and at least five times as many smaller size orifices to form filaments, attenuating the filaments into fibers and collecting the attenuated fibers to form the nonwoven web. The web is especially well suited to the manufacture of self-supporting three dimensional articles such as molded cup-shaped respirators and pleated air filters.

Abstract: A molded respirator is made from a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled continuous monocomponent polymeric microfibers and larger size fibers of the same polymeric composition. The respirator is a cup-shaped porous monocomponent monolayer matrix whose matrix fibers are bonded to one another at at least some points of fiber intersection. The matrix has a King Stiffness greater than 1 N. The respirator may be formed without requiring stiffening layers, bicomponent fibers, or other reinforcement in the filter media layer.

Abstract: A dust collection device for a sanding tool includes a bag having a sidewall with an inner surface and a coupler attacked to the bag. The sidewall comprises at least one filter layer and an outer support layer. A sleeve having an outer surface, a sleeve sidewall, a first end, a second end, and at least one gap at either the first end or the second end is positioned within the bag. The sleeve's first end is positioned adjacent the coupler to direct incoming air towards the sleeve and the sleeve is positioned within the bag such that a bypass volume is present between the outer surface and the inner surface.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled larger size and smaller size continuous monocomponent polymeric fibers of the same polymeric composition. Rows of pleats are formed in the nonwoven web, and the pleated web is cut to a desired size and shape to provide a filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers or other reinforcing measures in the filter media layer.

Abstract: A porous monocomponent nonwoven web contains a bimodal mass fraction/fiber size mixture of intermingled continuous microfibers and larger size fibers of the same polymeric composition. There are at least five times as many microfibers as larger size fibers, and a histogram of the mass fraction of fibers vs. fiber size exhibits a larger size fiber mode greater than 10 ?m. The web may be made by flowing fiber-forming material through a die cavity having larger size orifices and at least five times as many smaller size orifices to form filaments, attenuating the filaments into fibers and collecting the attenuated fibers to form the nonwoven web. The web is especially well suited to the manufacture of self-supporting three dimensional articles such as molded cup-shaped respirators and pleated air filters.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled larger size and smaller size continuous monocomponent polymeric fibers of the same polymeric composition. Rows of pleats are formed in the nonwoven web, and the pleated web is cut to a desired size and shape to provide a filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers or other reinforcing measures in the filter media layer.

Abstract: Shaped filtration articles are made from a monocomponent nonwoven web formed by flowing first and second fiber-forming materials of the same polymeric composition through first and second die cavities in respective fluid communication with first and second sets of orifices in a meltblowing die tip. The first fiber-forming material flows at a lesser flow rate or viscosity through the first die cavity and first set of orifices to form a set of smaller size filaments and the second fiber-forming material flows at a greater flow rate or viscosity through the second die cavity and second set of orifices to form a set of larger size filaments. The collected nonwoven web contains a meltblown bimodal mass fraction/fiber size mixture of intermingled continuous microfibers and larger size fibers of the same polymeric composition.