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 filtering face-piece respirator 10 that includes a harness 14 and a mask body 12. First and second bond lines 30a, 30b are located on opposing sides of the mask body 12 and join a top portion 18 of the mask body 12 to the bottom portion 20. The first and second bond lines 30a, 30b extend from the frontal line of demarcation 22 to upper and lower perimeter segments 24a, 24b. The upper and lower perimeter segments 24a, 24b have an upper linear segment 32a and a lower linear segment 32b, respectively, located between first and second curved portions 34a, 34b. The first and second curved portions 34a, 34b each extend from the respective upper or lower linear segment 32a, 32b to the first and second bond lines 30a, 30b. The invention provides a more rounded finish to the mask body perimeter, which enables the mask body to exhibit a more comfortable fit.

Abstract: A flat-fold filtering face piece respirator 10 that comprises a mask body 12 that has a transversely-extending line of demarcation 22 and a longitudinal axis 34. First and second weld patterns 32a, 32b are disposed above and not traversing the line of demarcation on each side of the longitudinal axis 34, respectively. Third and fourth weld patterns 32c, 32d are disposed below and not crossing the line of demarcation 22 on each side of the longitudinal axis 34, respectively. Each of the first, second, third, and fourth weld patterns 32a-32d is a two-dimensional enclosed pattern. This combined weld patterns can provide a mask body that exhibits crush resistance without the need for additional or heavier layers, which may cause higher pressure drops across the filtering structure.

Abstract: A filtering face-piece respirator 10 that comprises a mask body 12 and a harness 14. The mask body 12 includes a supporting frame structure 16 and a filtering structure 18. The frame structure is injection molded onto the filtering structure 18 such that the frame structure 16 becomes bonded to the filtering structure 18. A mask body having such a support structure allows the filtering structure to follow its configuration closely, providing improved aesthetics and collapse resistance to the resulting article.

Abstract: A respirator 10 that has a harness 14 and a mask body 12 that is joined to the harness 14. The mask body 12 includes a filtering structure 16 that may contain a plurality of layers of nonwoven fibrous material 58, 60, 62. The layers of nonwoven fibrous material 58, 60, 62 have a thickness A and are welded together by at least two parallel weld lines 34?, 34? that are spaced at 0.5 to 6 times A. A mask body that uses parallel weld lines may exhibit better resistance to collapse and may be manufactured at faster speeds than similar structures which use single weld lines of comparable width.

Abstract: A joined filter media pleat pack assembly comprises at least two filter media pleat packs, wherein each pleat comprises a root and a crown, wherein a seam between each filter media pleat pack is at least one of: (a) structure wherein the pleats, crowns, and roots of one filter media pleat pack are interleaved or nested with the corresponding structure of an adjacent filter media pleat pack or (b) structure wherein at least a portion of the terminal edges of adjacent filter media pleat packs are mitered at complimentary angles and assembled in mating relation.

Abstract: The present invention is a filter that includes a length of filter media and a continuous, substantially nonlinear adhesive strand. The filter media has a front face and a rear face. The filter media has a plurality of pleats defined by a plurality of fold lines, each fold line being intermediate oppositely sloping first and second wall surfaces. The plurality of fold lines comprise a first plurality of pleat tips and a second plurality of pleat valleys. The adhesive strand is provided on the front face of the filter media in discontinuous contact with the filter media. The adhesive strand contacts the filter media at a pleat tip and contacts the filter media at a portion of a first wall surface and contacts the filter media at a portion of a second wall surface.

Abstract: Face masks that are provided in a generally flat configuration and are capable of being expanded to a cup-shaped configuration. Such masks include at least one porous layer that includes at least one pleat and that is capable of being expanded by at least partially unfolding the at least one pleat. The mask further includes at least one stiffening element that comprises at least one engaging feature. Upon expanding the porous layer, the engaging feature engages with the porous layer so as to enhance the ability of the mask to maintain the expanded, cup-shaped configuration.

Abstract: An filtering face-piece respirator that includes a mask body 12 and a harness 14. The mask body includes a support structure 16, filtering structure 18, and a face seal element 40. The face seal element 40 is overmolded onto at least a portion of a perimeter of the support structure of the mask body. The overmolding of the face seal member to the support structure allows the face seal to become firmly secured to the mask body at its perimeter.

Abstract: A filtering face-piece respirator 10 that comprises a mask body 12 and a harness 14. The mask body 12 includes a supporting frame structure 16 and a filtering structure 18. The frame structure is injection molded onto the filtering structure 18 such that the frame structure 16 becomes bonded to the filtering structure 18. A mask body having such a support structure allows the filtering structure to follow its configuration closely, providing improved aesthetics and collapse resistance to the resulting article.

Abstract: Face masks that are provided in a generally flat configuration and are capable of being expanded to a cup-shaped configuration. Such masks include at least one porous layer that includes at least one pleat and that is capable of being expanded by at least partially unfolding the at least one pleat. The mask further includes at least one stiffening element that comprises at least one engaging feature. Upon expanding the porous layer, the engaging feature engages with the porous layer so as to enhance the ability of the mask to maintain the expanded, cup-shaped configuration.

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.