Abstract: A face mask (10) covers the nose and mouth of the wearer and includes a band (24) to retain the mask member (12) in position. The band attaches at the sides (20) of the mask and extends around the ears of the wearer and loops through orifices (32). The band (24) extends around the back of the neck and provides for retaining the mask (10) at the front of the wearer when not worn. Ends (26) of the band (24) are elastic to provide a snug fit for the mask (10).

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: Fibrous webs of bicomponent fibers are made by extruding a layered molten mass through a row of side-by-side orifices into a high-velocity gaseous stream. Bicomponent fibers of small size can be obtained, and the webs offer unique properties.

Abstract: A respiratory mask 1 has a molded, cup-shaped, shape-retaining shell 10 on the concave side of which is a layer of filter material 11 and, on the concave side of the filter material, without any intermediate shape-retaining layer, a layer of nonwoven material 12. The layer of filter material 11 and the inside layer 12 are conformed into the cup-shaped configuration of the shape-retaining shell 10. The inside layer 12 is preferably a smooth BMF material offering improved comfort to the wearer.

Abstract: A face mask (10) covers the nose and mouth of the wearer and includes a band (24) to retain the mask member (12) in position. The band attaches at the sides (20) of the mask and extends around the ears of the wearer and loops through orifices (32). The band (24) extends around the back of the neck and provides for retaining the mask (10) at the front of the wearer when not worn. Ends (26) of the band (24) are elastic to provide a snug fit for the mask (10).

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 method for forming an earplug containment device comprising providing at least one thin-walled, hollow sleeve having an inside diameter less than the diameter of the human ear canal, compressing a slow-recovery earplug having a diameter greater than that of the human ear canal to a cross-sectional size less than that of said sleeve, and inserting said compressed earplug into said sleeve.

Abstract: A method of making a microfibrous sorbent article is provided. The method includes the steps of a) extruding molten thermoplastic fiber forming polymer from multiple orifices in a fiber-forming die, said orifices being aligned along the face of the die; b) attenuating the fibers in a stream of hot air to form a fiber stream of microfibers; and c) collecting said microfibers on a collector having a forming surface, said surface being aligned with said die and substantially parallel to and equidistant from said die such that the fibers form a spirally wound microfibrous sorbent article which is supported on its exterior surface by said forming surface and which is drawn across said forming surface substantially parallel to said die. Also provided is a microfibrous sorbent article prepared according to the method.

Abstract: A method of forming a cup-shaped, non-woven fibrous shaping layer for a filtering face mask. The method includes the steps: (a) heating a non-woven fibrous web that contains at least 40 weight percent thermally bonding fibers, where at least 10 weight percent of the fibrous material is bicomponent fibers, to a temperature at which the thermally bonding fibers, including at least one component of the bicomponent fibers, are softened; and then (b) molding the heated non-woven fibrous web, while the thermally bonding fibers and the at least cone component of the bicomponent fibers are still soft, in a mold having molding members that are at a temperature below the softening temperatures of the thermally bonding fibers, including all components of the bicomponent fibers.

Abstract: A device for compressing slow recovery earplugs is provided. The device comprises a flexible strip having an elongate compression portion having first and second ends and a base portion at the first end of the compression portion, the base portion having a width greater than that of the compression portion, an opening proximate the compression portion and having a width transverse of the compression portion larger than the width of the compression portion, the compression portion being at least 15 mm wide and of sufficient length that the second end can pass through the opening to form a tubular compression means having a diameter at least that of a slow recovery earplug.

Abstract: A shipping or secondary container, which can safely transport a plurality of breakable primary containers of a variety of sizes and shapes, has a pair of rigid shells that mate. A batt of sorptive material fills each shell, and a normally tacky, discontinuous adhesive layer covers the exposed face of at least one batt. The shells can be vacuum formed from a sheet of thermoplastic resin that is 0.25 to 0.5 mm in thickness. The two shells preferably are identical to each other. To permit them to interlock, each shell has an upstanding wall that is formed with both tongues and grooves which telescopically mate with the tongues and grooves of the other shell.

Abstract: A microporous particulate-filled thermoplastic polymeric article is provided. The article can be in the form of a film, a fiber, or a tube. The article has a thermoplastic polymeric structure having a plurality of interconnected passageways to provide a network of communicating pores. The microporous structure contains discrete submicron or low micron-sized particulate filler, the particulate filler being substantially non-agglomerated.

Abstract: New molded fibrous filtration face masks that are highly resilient and shape-retaining are provided using one or more molded fibrous shaping layers, with a fibrous filtration layer disposed on one side of or between the molded fibrous shaping layers; the molded fibrous shaping layers having a total basis weight of at least 150 g/m2, and at least one of the fibrous shaping layers having an average density over the central area of the face mask of no greater than about 0.2 g/cc, such that at bends of the layer during deformation of the face mask the layer elastically deforms and tends to return to its original thickness and shape when the deforming pressure is removed.

Abstract: Fibrous webs of bicomponent fibers are made by extruding a layered molten mass through a row of side-by-side orifices into a high-velocity gaseous stream. Bicomponent fibers of small size can be obtained, and the webs offer unique properties.