Abstract: A personal respiratory protection device that comprises a multilayer body including a stiffening layer, filter media layer(s) and inner or outer cover layer(s). The mask body includes a central portion between first and second portions, the central portion being defined by a fold, bond, weld, seam, or combination thereof and having a width of about 160 to 220 mm and a height of about 30 to 110 mm. The device is capable of being folded flat for storage with the first portion in at least partial face-to-face contact with a surface of the central portion and the second portion contacting a surface of the first portion. When unfolded for use the device is capable of forming a cup-shaped off the face air chamber over the nose and mouth of a wearer.

Abstract: A personal respiratory protection device that includes a multi-layered structure and first and second means for attaching a headband. The multilayered structure includes a filter medium and is divided into a flat upper panel, a flat non-rectangular central panel, and a lower panel. The central panel is separated from each of the upper and lower panels by first and second lines of demarcation. The first and second lines of demarcation converge towards the first and second means for attaching a headband. The multi-layered structure can be folded at the respective lines of demarcation so that the device can be folded flat for storage and can be opened to form a cup-shaped off the face air chamber over the nose and mouth of the wearer while an upper peripheral edge and a lower peripheral edge contact the wearer's face when the device is in use.

Abstract: A personal respiratory protection device includes a multi-layered structure and first and second means for attaching a headband to hold the device in position on a wearer's face. The multilayered structure includes a filter medium and is divided into a flat upper panel having an upper peripheral edge, a flat non-rectangular central panel and a lower panel having a lower peripheral edge. The central panel is separated from each of the upper and lower panels by first and second lines of demarcation. The first and second lines of demarcation converge towards the first and second means for attaching a headband. The multi-layered structure is capable of being folded at the respective lines of demarcation so that the device can be folded flat for storage and can be opened to form a cup-shaped off the face air chamber over the nose and mouth of the wearer while the upper peripheral edge and the lower peripheral edge contact the wearer's face when the device is in use.

Abstract: A face mask for filtering contaminants from the air. The face mask includes a harness for securing the mask over the nose and mouth of the wearer and a nonwoven fibrous layer attached to the harness. The nonwoven fibrous layer contains at least 40 weight percent thermally bonding fibers, where at least 10 weight percent of the fibers in the nonwoven fibrous layer are bicomponent fibers. The nonwoven fibrous layer is molded in a cup-shaped configuration and has a surface fuzz value of not less than 7.5 after being subjected to a surface fuzz abrasion test.

Abstract: A personal respiratory protection device that comprises a mask body and an exhalation valve that is secured to the mask body. The mask body includes (i) a flat central panel; (ii) a flat first panel joined to the central panel through a fold-line, seam weld, or bond, the fold-line, seam, weld or bond of the first panel being substantially coextensive with an edge of the central panel; (iii) a flat second panel joined to the central panel through a fold-line, seam, weld or bond, the fold-line, seam, weld or bond of the second panel being substantially coextensive with an edge of the central panel. At least one of the center, first and second panels includes filter media. The device is capable of being folded for storage with the first and second panels in at least partial face-to-face contact with a common surface of the central panel and, during use, is capable of forming, over the nose and mouth of the wearer, a cup-shaped air chamber having a face-contacting periphery.

Abstract: Fold-flat personal respiratory protection devices that have a flat substantially rectangular central portion having first and second edges, at flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Fold-flat personal respiratory protection devices that have a flat substantially rectangular central portion having first and second edges, at flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: A method of making a personal respiratory protection device. The method comprises: (a) forming a multi-layered structure that comprises a first cover web, a filtration layer that comprises a web that contains electrically-charged microfibers, and a second cover web; and (b) adapting the multi-layered structure into a first panel, a central panel, and a second panel such that the central panel is separated from each of the first and second panels by first and second lines of demarcation, and each of the first, second, and central panels is non-pleated. The first and second cover webs are disposed on first and second opposing sides of the filtration layer, respectively, and at least one of the cover webs comprises spunbond fibers. The resulting respiratory protection device is capable of being folded flat at the respective lines of demarcation for storage and can be opened to form a cup-shaped air chamber over the nose and mouth of the wearer when in use.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge through either a fold-line, seam, weld or bond that is substantially coextensive with the first edge, and a flat second member joined to the second edge through either a fold-line, seam, weld or bond that is substantially coextensive with the second edge. At least one of the central portion and first and second members are formed from filter media. The device is capable of being folded flat for storage with the first and second members being in at least partial face-to-face contact with a common surface of the central portion and, during use, is capable of forming a cup-shaped air chamber over the nose and mouth of the wearer.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Multilayer meltblown fibrous webs, as well as apparatus and methods of forming the webs. The webs are produced on a rotating collector that also moves parallel to its longitudinal axis. The webs are thus formed in a helical process, and the resulting tubular web is separated in a direction parallel to a helix angle. By separating the tubular web in a direction parallel to the helix angle, a flat multilayer meltblown fibrous web is provided that allows for incorporation of feathered edges formed during the article's manufacture.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.

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: Multilayer meltblown fibrous webs, as well as apparatus and methods of forming the webs. The webs are produced on a rotating collector that also moves parallel to its longitudinal axis. The webs are thus formed in a helical process, and the resulting tubular web is separated in a direction parallel to a helix angle. By separating the tubular web in a direction parallel to the helix angle, a flat multilayer meltblown fibrous web is provided that allows for incorporation of feathered edges formed during the article's manufacture.

Abstract: Fold-flat personal respiratory protection devices are provided. The devices have a flat central portion having first and second edges, a flat first member joined to the first edge of the central portion through either a fold-line, seam, weld or bond, said fold, bond, weld or seam of the first member being substantially coextensive with said first edge of said central portion, and a flat second member joined to the second edge of the central portion through either a fold-line, seam, weld or bond, the fold, bond, weld or seam of the second member being substantially coextensive with said second edge of said central portion. At least one of the central portion and first and second members are formed from filter media.