Abstract: A filtering face mask that has a mask body and an exhalation valve. The mask body is adapted to fit over the nose and mouth of a wearer. The exhalation valve is attached to the mask body and includes a valve seat that comprises a seal surface, an orifice that is circumscribed by the seal surface, a flap-retaining surface, and a single flexible flap that has a fixed portion and a free portion and first and second opposing ends. The first end of the single flexible flap is associated with the fixed portion of the flap so as to remain at rest during an exhalation, and the second end is associated with the free portion of the flexible flap so as to be lifted away from the seal surface during an exhalation. The second end also is located below the first end when the filtering face mask is worn on a person. The flexible flap is positioned on the valve seat such that the flap is pressed towards the seal surface in an abutting relationship therewith when a fluid is not passing through the orifice.

Abstract: A filtering face mask that has a mask body and an exhalation valve. The mask body is adapted to fit over the nose and mouth of a wearer. The exhalation valve is positioned on the mask body substantially opposite to a wearer's mouth. The exhalation valve comprises a valve seat that has a seal surface, an orifice that is circumscribed by the seal surface, and cross members that extend across the orifice to create a plurality of openings within the orifice. The valve also includes a single flexible flap that has a fixed portion and a free portion and first and second opposing ends. The first end of the single flexible flap is associated with the fixed portion of the flap so as to remain at rest during an exhalation, and the second end being associated with the free portion of the flexible flap so as to be lifted away from the seal surface during an exhalation. The second end also is located below the first end when the filtering face mask is worn on a person.

Abstract: A method of making a filtering face mask, which method includes the steps of: (a) providing (i) a valve seat that comprises an orifice and a seal surface, wherein the orifice allows air to pass therethrough and is surrounded by the seal surface, and (ii) a single flexible flap; (b) supporting the single flexible flap non-centrally and operatively relative to the orifice of the valve seat to form an exhalation valve, the single flexible flap being supported such that there is an imposed curved profile that extends from a first point where a stationary portion of the flap is supported on the valve seat to a second point where a free portion of the flap contacts a seal surface; and (c) attaching the exhalation valve to a mask body that is adapted to fit over the nose and mouth of a person.

Abstract: A filtering face mask that has a mask body and an exhalation valve. The mask body is adapted to fit over the nose and mouth of a wearer. The exhalation valve is attached to the mask body and has a valve seat that includes a seal surface and an orifice that is circumscribed by the seal surface. The valve also has a single flexible flap that has a fixed portion and a free portion and first and second opposing ends. The first end of the single flexible flap is associated with the fixed portion of the flap so as to remain at rest during an exhalation, and the second end is associated with the free portion of the flexible flap so as to be lifted away from the seal surface during an exhalation. The second end also is located below the first end when the filtering face mask is worn on a person. The flexible flap is positioned on the valve seat such that the flap is pressed towards the seal surface in an abutting relationship therewith when a fluid is not passing through the orifice.

Abstract: Filtering face mask 10 has a mask body 12 and an exhalation valve 14. The mask body 12 is adapted to fit over the nose and mouth of a person, and the exhalation valve 14 is attached to the mask body 12. The exhalation valve 14 has a valve seat 26 and a single flexible flap 24. The valve seat 26 includes a seal surface 31 and an orifice 32. The orifice 32 is circumscribed by the seal surface 31. The single flexible flap 24 has a fixed portion 28 and one free portion 38. The one free portion 38 has a free end, and the fixed portion 28 is located off-center of the flexible flap 24 away from the free end and is secured to the valve seat 26 outside the orifice 32. The one free portion 38 is pressed toward the seal surface 31 when the wearer is neither inhaling or exhaling. The free portion 38 can be lifted from the seal surface 31 during an exhalation.

Abstract: A filtering face mask that comprises a mask body that is adapted to fit over the nose and mouth of a wearer, the mask body comprising a filtration layer through which inhaled air may pass before being inhaled by a wearer of the face mask; and an exhalation valve that is attached to the mask body, the exhalation valve allowing air exhaled by a wearer to pass from an interior of the mask body to its exterior without having to pass through the filtration layer, the exhalation valve comprising: a valve seat that comprises: a seal surface; and an orifice that is circumscribed by the seal surface; and a single flexible flap that has one fixed portion and one free portion and a circumferential edge, the circumferential edge having a first segment that is associated with the one fixed portion of the flap so as to remain at rest during an exhalation and having a second segment that is associated with the one free portion of the flexible flap so as to be lifted away from the seal surface during an exhalation, the secon

Abstract: An exhalation valve 14 for a filtering face mask 10 has a flexible flap 24 that makes contact with a curved seal ridge 30 of a valve seat 26 when the valve 14 is in the closed position. The curvature of the seal ridge 30 corresponds to a deformation curve exhibited by the flexible flap 24 when secured as a cantilever at one end and exposed at its free portion to a uniform force and/or a force of at least the weight of the free portion of the flexible flap. A seal ridge curvature corresponding to a flexible flap exposed to uniform force allows the flexible flap 24 to exert a generally uniform pressure on the seal ridge to provide a good seal. A ridge curvature corresponding to a flexible flap exposed to a force of at least the weight of the flap's free portion allows the flexible flap 24 to be held in an abutting relationship to the seal ridge 30 under any static orientation by a minimum amount of force, thereby providing a face mask 10 with an extraordinary low pressure drop during an exhalation.

Abstract: A filtering face mask that comprises a mask body that is adapted to fit over the nose and mouth of a wearer, the mask body comprising a filtration layer through which inhaled air may pass before being inhaled by a wearer of the face mask; and an exhalation valve that is attached to the mask body, the exhalation valve allowing air exhaled by a wearer to pass from an interior of the mask body to its exterior without having to pass through the filtration layer, the exhalation valve comprising: a valve seat that comprises: a seal surface; and an orifice that is circumscribed by the seal surface; and a single flexible flap that has one fixed portion and one free portion and a circumferential edge, the circumferential edge having a first segment that is associated with the one fixed portion of the flap so as to remain at rest during an exhalation and having a second segment that is associated with the one free portion of the flexible flap so as to be lifted away from the seal surface during an exhalation, the secon

Abstract: A filtering face mask that comprises a mask body adapted to fit over the nose and mouth of a person; and an exhalation valve that is attached to the mask body. The exhalation valve comprises a valve seat and a flexible flap. The valve seat has an orifice through which fluid can pass and is surrounded by the seal surface. The flexible flap is operatively supported relative to the valve seat and pressed against the seal surface of the valve seat in a closed state of the exhalation valve. The flexible flap assumes in its closed state, a curved profile in a cross-sectional view thereof The curved profile comprises a curve that extends from a first point where a first portion of the flexible flap contacts the seal surface to a second point where a second portion of the flexible flap contacts the seal surface.

Abstract: A multi-part headband attachable to a face mask blank and a method of attaching the same. The multi-part headband has a unit length corresponding to the distance between the attachment locations as measured along a surface of the face mask blank or along an axis intersecting the attachment locations, to facilitate material handling and attachment using high speed manufacturing equipment. The headband material is positioned along the headband path and attached at the left and right headband attachment locations. At least one longitudinal score line is formed in the headband material extending generally along the headband path, whereby the at least one longitudinal score line defines a multi-part headband. The face mask blank may comprise a molded cup-shaped face mask, a flat folded face mask or a variety of other face mask constructions.

Abstract: A composite headband attachable to a face mask and a method for attaching same. The composite headband has at least one discrete elastomeric core and at least one continuous thermoplastic skin layer secured to the elastomeric core. The composite headband has a first modulus in an unactivated state and a second, lower modulus in an activated state. The thermoplastic skin layer forms a microtextured permanently deformed skin layer when the composite headband is in the activated state. In one embodiment, the at least one elastomeric core and the at least one thermoplastic layer are in continuous contact in the activated state. The composite headband is positioned along the headband path and attached to at least one of the left and right headband attachment locations. The headband path is either an axis intersecting the left and right headband attachment locations or a path that generally follows a contour of a surface of the face mask blank.

Abstract: A multi-part headband attachable to a face mask blank and a method of attaching the same. The multi-part headband has a unit length corresponding to the distance between the attachment locations as measured along a surface of the face mask blank or along an axis intersecting the attachment locations, to facilitate material handling and attachment using high speed manufacturing equipment. The headband material is positioned along the headband path and attached at the left and right headband attachment locations. At least one longitudinal score line is formed in the headband material extending generally along the headband path, whereby the at least one longitudinal score line defines a multi-part headband. The face mask blank may comprise a molded cup-shaped face mask, a flat folded face mask or a variety of other face mask constructions.

Abstract: An exhalation valve 14 for a filtering face mask 10 has a flexible flap 24 that makes contact with a curved seal ridge 30 of a valve seat 26 when the valve 14 is in the closed position. The curvature of the seal ridge 30 corresponds to a deformation curve exhibited by the flexible flap 24 when secured as a cantilever at one end and exposed at its free portion to a uniform force and/or a force of at least the weight of the free portion of the flexible flap. A seal ridge curvature corresponding to a flexible flap exposed to uniform force allows the flexible flap 24 to exert a generally uniform pressure on the seal ridge to provide a good seal. A seal ridge curvature corresponding to a flexible flap exposed to a force of at least the weight of the flap's free portion allows the flexible flap 24 to be held in an abutting relationship to the seal ridge 30 under any static orientation by a minimum amount of force, thereby providing a face mask 10 with an extraordinary low pressure drop during an exhalation.

Abstract: The invention discloses an oleophobic, hydrophobic, water repellent, moisture vapor and air permeable, heat sealable, microporous membrane material suitable for garment applications. The membrane material comprises a polyolefin polymer, a processing compound which is miscible with the polymer at its melt temperature but phase separates when the polymer is cooled to or below its melt temperature, and a fluorochemical composition. The membrane material is oriented in at least one direction. The membrane materials retain their repellency and moisture vapor permeable properties for extended periods of time in garment applications which expose the membrane materials to perspiration residues which are known to generally contaminate and ultimately destroy the repellency properties of conventional liquid repellent, moisture vapor permeable treatments.

Abstract: An exhalation valve 14 for a filtering face mask 10 has a flexible flap 24 that makes contact with a curved seal ridge 30 of a valve seat 26 when the valve 14 is in the closed position. The curvature of the seal ridge 30 corresponds to a deformation curve exhibited by the flexible flap 24 when secured as a cantilever at one end and exposed at its free portion to a uniform force and/or a force of at least the weight of the free portion of the flexible flap. A seal ridge curvature corresponding to a flexible flap exposed to uniform force allows the flexible flap 24 to exert a generally uniform pressure on the seal ridge to provide a good seal. A seal ridge curvature corresponding to a flexible flap exposed to a force of at least the weight of the flap's free portion allows the flexible flap 24 to be held in an abutting relationship to the seal ridge 30 under any static orientation by a minimum amount of force, thereby providing a face mask 10 with an extraordinary low pressure drop during an exhalation.

Abstract: The invention discloses an oleophobic, hydrophobic, water repellent, moisture vapor and air permeable, heat sealable, microporous membrane material suitable for garment applications. The membrane material comprises a polyolefin polymer, a processing compound which is miscible with the polymer at its melt temperature but phase separates when the polymer is cooled to or below its melt temperature, and a fluorochemical composition. The membrane material is oriented in at least one direction. The membrane materials retain their repellency and moisture vapor permeable properties for extended periods of time in garment applications which expose the membrane materials to perspiration residues which are known to generally contaminate and ultimately destroy the repellency properties of conventional liquid repellent, moisture vapor permeable treatments.

Abstract: The present invention provides a liquid sorbent article comprising at least two contiguous layers formed from a single sheet, said layers being joined at a fold in said sheet and being intermittently releasably bonded together.

Abstract: A harness assembly for disposable respirators and more particularly to a respirator harness assembly having an open light-weight elastic loop with a single point connector which enables the respirator to be easily and quickly applied, and provides for temporary "storage" of the respirator during periods of non-use is disclosed.

Abstract: Disposable adherent collars based on low cost supple sheets carrying a low-adherency pressure sensitive adhesive are disclosed. The adherent collars of the present invention are significantly more comfortable to wear than prior art adherent collars due to the suppleness of the sheet used in the collars, and to the low-adherency character of the PSA, achieved preferably through the use of a discontinuous layer of PSA material. Because of the suppleness of the sheet the low-adherency adhesive is effective to hold the sheet in place.