Abstract: Various embodiments of a filtering face-piece respirator and a method of forming such respirator are disclosed. The filtering face-piece respirator includes a mask body having a filtering structure and an attachment region disposed on the mask body that includes a connected portion and an aperture disposed in the connected portion. Two or more layers of the filtering structure are connected together to form the connected portion. The filtering face-piece respirator further includes an adjustable strap having a first end and a second end, where the first end of the strap is threaded through the aperture of the attachment region such that the strap is connected to the attachment region. The aperture mechanically retains the strap.

Abstract: A flat-fold, filtering, face-piece respirator that has a harness, a mask body, and first and second flanges. The mask body is capable of being folded flat for storage and can be opened into a cup-shaped configuration for use. The mask body comprises a filtering structure and has the first and second flanges disposed on first and second mask body sides. The first and second flanges project both laterally x and frontally y from the mask body. The provision of the flanges on each side of the respirator is beneficial to ease of mask donning, doffing, and adjustment, and to face fit and maintaining the open shape or configuration of the mask body.

Abstract: A filtering facepiece respirator 10 that includes a harness 14 and a mask body 12 that has a filtering structure 16 that contains one or more layers of filter media 62 and that has a perimeter 24. The mask body also has first and second flanges 30a, 30b located on opposing sides of the filtering structure 16. The first and second flanges 30a, 30b each have a leading edge 33 and are each folded inwardly in contact with the filtering structure 16. The in-contact configuration exists when the mask body 12 is open in an in-use configuration. The leading edge 33 of each flange 30a, 30b is configured to match the mask body perimeter 24 when the flanges 30a, 30b are folded inwardly in contact with the filtering structure 16.

Abstract: A flat-fold, filtering, face-piece respirator 10 that has a harness 14, a mask body 12, and first and second flanges 30a, 30b. The mask body 12 is capable of being folded flat for storage and can be opened into a cup-shaped configuration for use. The mask body 12 includes a filtering structure 16 and has the first and second flanges 30a, 30b disposed on first and second mask body sides. The first and second flanges 30a, 30b project both laterally x and frontally y from the mask body 12. The provision of the flanges on each side of the respirator is beneficial to ease of mask donning, doffing, and adjustment, and to face fit and maintaining the open shape or configuration of the mask body.

Abstract: A foldable filtering face-piece respirator is disclosed. The respirator includes a mask body having a line of demarcation that separates the mask body into a first portion and a second portion. The respirator also includes an exhalation valve positioned on the line of demarcation and in a central area of the mask body such that the exhalation valve is positioned essentially over a wearer's mouth during use. The line of demarcation is discontinuous at the location of the valve.

Abstract: Various embodiments of a respirator and a method of making such respirator are disclosed. The respirator includes a mask body and a harness connected to the mask body. The mask body includes a filtering structure having a central panel, an upper panel separated from the central panel by a first line of demarcation, and a lower panel separated from the central panel by a second line of demarcation. The mask body further includes a bisecting fold, and a transversely-extending three-layer pleat disposed in a central panel of a filtering structure of the mask body. The transversely-extending three-layer pleat is formed in the mask body and is sealed to itself at a first seal location disposed on a right side of the mask body and a second seal location disposed on a left side of the mask body.

Abstract: A filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a multi-layer filtering structure 16. The respirator includes a cushioning member 64 positioned proximate the nose area of the mask body 12, enveloped by a layer of the filtering structure 16. The cushioning member 64 is a compressible material and may be elastic. The cushioning member 64 can be positioned directly opposite of a nose clip 56.

Abstract: Various embodiments of a respirator and a method of making such respirator are disclosed. In one or more embodiments, the respirator includes a mask body and a harness attached to the mask body. The mask body can include an outer cover web, an inner cover web, a filtration layer disposed between the outer cover web and the inner cover web, and a contrast layer disposed between the outer cover web and the inner cover web in a sinus region of the mask body. A portion of the contrast layer can be visible through an outer surface of the outer cover web to form a contrast region of the mask body, where the outer surface of the outer cover web faces away from the filtration layer.

Abstract: A filtering face-piece respirator (10) having a cup-shaped, molded mask body (20) and having integral nose pads (21, 26) provided by inwardly-folded tabs (41, 46), which tabs (41, 46) are integral extensions of at least one layer of the mask body (20).

Abstract: A cup-shaped filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a multi-layer filtering structure 16. The mask body 12 includes at least one dart 60 permanently bonded in the filtering structure 16, the dart 60 tapering from a center plane 32 of the mask body 12 to a side edge of the mask body. The dart 60 inhibits collapse of the cup-shaped form of the respirator 10.

Abstract: A filtering face-piece respirator 10 that includes a mask body 12 and a harness 14. The mask body 12 has a major portion 28 that contains one or more layers of filter media 62 and that has first and second flanges 30a, 30b located on opposing sides of the major portion 28 at first and second lines of demarcation 36a, 36b. The first and second flanges 30a, 30b are capable of folding downwardly toward the major portion 28. The harness 14 includes one or more straps 26, 27 that each have first and second ends 29a, 29b. The first and second straps are secured to the first and second flanges 30a, 30b, such that there is a strap attachment point spaced at least one centimeter from the line of demarcation. The strap tension and spacing from the line of demarcation causes the flap to be folded downwardly into contact with the major portion to improve crush resistance.

Abstract: A foldable filtering face-piece respirator is disclosed. The respirator includes a mask body having a line of demarcation that separates the mask body into a first portion and a second portion. The respirator also includes an exhalation valve positioned on the line of demarcation and in a central area of the mask body such that the exhalation valve is positioned essentially over a wearer's mouth during use. The line of demarcation is discontinuous at the location of the valve.

Abstract: A filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a multi-layer filtering structure 16. The mask body 12 includes an upper interior perimeter segment 24a formed from the filtering structure 16 and configured to fit against the face of the respirator wearer. Present in the upper interior perimeter segment 24a is a nose notch 52, 62, which is an area void of filtering structure 16.

Abstract: A filtering face-piece respirator dispenser 10 having a container 14 that has a constriction aperture 20 and a plurality of filtering, face-piece respirators 12 disposed within the container 14 in a stacked, at least partially-folded arrangement. The stacked respirators 12 include an outermost respirator 12a. The constriction aperture 20 is adapted to allow for the outermost flat filtering face-piece respirator 12a to be manually withdrawn from the container 14 such that the outermost respirator 12a goes from the at least partially-folded condition to an open condition, making the respirator more ready for donning.

Abstract: A flat fold filtering face piece respirator 10 that includes a mask body 12 and a harness 14. The mask body 12 includes a filtering structure 16 that contains a cover web 48, 50 and a filtration layer 52 that contains electrically-charged microfibers. The filtering structure 16 is folded over upon itself in a nose region 32 of the mask body 12 to be at least 1 centimeter or more wide and to extend across the upper perimeter of the mask body in a generally straight line when the respirator is in the folded condition. The filtering structure 16 has a deflection greater than about 0.5 millimeters and has a recoverability of at least 40% in the folded condition. A mask body having this construction is beneficial in that it does not need to use a nose foam to obtain a snug fit over the nose.

Abstract: Various embodiments of a respirator and a method of making such respirator are disclosed. In one or more embodiments, the respirator includes a mask body and a harness attached to the mask body. The mask body can include an outer cover web, an inner cover web, a filtration layer disposed between the outer cover web and the inner cover web, and a contrast layer disposed between the outer cover web and the inner cover web in a sinus region of the mask body. A portion of the contrast layer can be visible through an outer surface of the outer cover web to form a contrast region of the mask body, where the outer surface of the outer cover web faces away from the filtration layer.

Abstract: Various embodiments of a respirator and a method of making such respirator are disclosed. In one or more embodiments, the respirator includes a mask body and a harness attached to the mask body. The mask body can include an outer cover web, an inner cover web, a filtration layer disposed between the outer cover web and the inner cover web, and a contrast layer disposed between the outer cover web and the inner cover web in a sinus region of the mask body. A portion of the contrast layer can be visible through an outer surface of the outer cover web to form a contrast region of the mask body, where the outer surface of the outer cover web faces away from the filtration layer.

Abstract: A horizontal flat-fold, filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a front surface, a first perimeter 24a, and a longitudinal axis 34. A nose clip 30 is secured to the mask body 12 centrally and adjacent to the first perimeter 24a of the mask body 12. An indicia 32 that is visible on the front surface of the mask body 12 in a vicinity of the nose clip 30 is provided to highlight a longitudinal axis of symmetry of the nose clip. The use of such an indicia, visible from the mask body front surface, enables a user to readily identify where the nose clip may be bent to prepare it for donning by the wearer.

Abstract: A filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a multi-layer filtering structure 16. The respirator includes a cushioning member 64 positioned proximate the nose area of the mask body 12, enveloped by a layer of the filtering structure 16. The cushioning member 64 is a compressible material and may be elastic. The cushioning member 64 can be positioned directly opposite of a nose clip 56.

Abstract: A filtering face-piece respirator 10 that includes a harness 14 and a mask body 12 that has a multi-layer filtering structure 16. The respirator includes a cushioning member 64 positioned proximate the nose area of the mask body 12, enveloped by a layer of the filtering structure 16. The cushioning member 64 is a compressible material and may be elastic. The cushioning member 64 can be positioned directly opposite of a nose clip 56.