Filtering face-piece respirator having support structure injection molded to filtering structure

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.

Respirator Having Corrugated Filtering Structure

Various embodiments of a filtering face-piece respirator and a method of making such respirator are disclosed. In one or more embodiments, the filtering face-piece respirator includes a mask body and a harness attached to the mask body. The mask body includes a corrugated filtering structure including peaks separated by valleys, and bridging filaments that are in discontinuous contact with at least one of an interior surface and an exterior surface of the corrugated filtering structure. The bridging filaments are attached to at least some of the peaks. 1. A filtering face-piece respirator comprising a mask body and a harness attached to the mask body , wherein the mask body comprises:a corrugated filtering structure comprising peaks separated by valleys; andelastic bridging filaments that are in discontinuous contact with at least one of an interior surface and an exterior surface of the corrugated filtering structure, wherein the elastic bridging filaments are attached to at least some of the peaks.2. The respirator of claim 1 , wherein portions of the elastic bridging filaments are melt bonded to at least some of the peaks.3. The respirator of claim 1 , wherein the peaks extend along a peak axis claim 1 , and further wherein at least some of the elastic bridging filaments are substantially perpendicular to the peak axis.4. The respirator of claim 1 , wherein an average filament spacing of the elastic bridging filaments is greater than 0 mm and no greater than 51 mm.5. The respirator of claim 1 , wherein the corrugated filtering structure comprises a nonwoven web comprising organic polymeric fibers.6. The respirator of claim 1 , wherein the peaks and the valleys of the corrugated filtering structure comprise an average radius of curvature of at least 2 mm.7. The respirator of claim 1 , wherein the corrugated filtering structure comprises a peak frequency of greater than 0 peaks per cm and no greater than 3 peaks per cm.8. The respirator of claim 1 , wherein the ...

FILTERING FACE-PIECE RESPIRATOR HAVING AN OVERMOLDED FACE SEAL

An filtering face-piece respirator that includes a mask body and a harness . The mask body includes a support structure , filtering structure , and a face seal element . The face seal element 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. 1. A filtering face-piece respirator that comprises:a) a harness; (i) a filtering structure;', '(ii) a support structure; and, 'b) a mask body that comprisesc) a face seal element that has been overmolded onto at least a portion of a perimeter of the support structure of the mask body.2. The filtering face-piece respirator of claim 1 , wherein the overmolded perimeter of the support structure includes incongruities.3. The filtering face-piece respirator of claim 1 , further including a respirator component that is held in place at least in part by the face seal element that has been overmolded onto the perimeter of the mask body support structure.4. The filtering face-piece respirator of claim 3 , wherein the at least one respirator component comprises a nose clip.5. The filtering face-piece respirator of claim 1 , wherein the face seal element is also overmolded onto a periphery of the filtering structure.6. The filtering face-piece respirator of claim 5 , wherein the filtering structure is juxtaposed against the support structure where the face seal element is overmolded onto the filtering structure.7. The filtering face-piece respirator of claim 1 , wherein the face seal element comprises a radially inwardly extending flange that has been molded into a three-dimensional configuration.8. The filtering face-piece respirator of claim 7 , wherein the face seal flange portion is made of a plastic material that is less than about 0.5 millimeters thick which can conform to the wearer's face during use.9. The filtering face-piece respirator of ...

MOLDED RESPIRATOR HAVING OUTER COVER WEB JOINED TO MESH

A respirator that has a mask body and a harness that is attached to the mask body . The mask body includes a filtering structure that has an inner cover web , an outer cover web that comprises melt-blown fibers and staple fibers, and a filtration layer that is located between the inner and outer cover webs . The mask body also has a mesh that is joined to the outer cover web . A respirator having this construction is more resistant to inward collapse of the filter media during breathing and is more aesthetically pleasing. 1. A filtering face-piece respirator that comprises: (i) an inner cover web;', '(ii) an outer cover web that comprises melt-blown fibers and staple fibers, the melt-blown fibers comprising a polymeric material that has a first melting point; and', '(iii) a filtration layer that is located between the inner and outer cover webs; and', '(iv) a plastic mesh that contains a polymeric material that has a second melting point and that is joined to the outer cover web in the mid region of the mask body, wherein the first and second melting points are similar; and, '(a) a shaped mask body that comprises a filtering structure that includes(b) a harness that is attached to the mask body.2. The filtering face-piece respirator of claim 1 , wherein the microfibers in the outer cover web are electrically charged.3. The filtering face-piece respirator of claim 1 , wherein the mesh is welded to the filtering structure at the perimeter.4. The filtering face-piece respirator of claim 3 , wherein the mesh contains cells that each have a hexagonal shape.5. The filtering face-piece respirator of claim 3 , wherein the mesh is welded to the filtering structure at the apex.6. The filtering face-piece respirator of claim 1 , wherein the first melting point is 130 to 170° C.7. The filtering face-piece respirator of claim 6 , wherein the second melting point is 130 to 170° C.8. The filtering face-piece respirator of claim 1 , wherein the first melting point is 140 to 160° C. ...

RESPIRATOR HAVING MOTTLED APPEARANCE

A filtering face-piece respirator that comprises a mask body and a harness that is attached to the mask body . The mask body comprises a shaping layer and a filtering structure that contains a filtering layer . The filtering structure also comprises an outer cover web that includes colored melt-blown fibers and staple fibers. The use of colored melt-blown fibers and staple fibers in an outer cover web provides the respirator with a mottled colored appearance—that is, the color does not appear uniform over the outer surface of the outer cover web. 1. A filtering face-piece respirator that comprises: (i) an outer cover web that comprises colored melt-blown fibers and staple fibers; and', '(ii) a filter layer; and, '(a) a mask body that includes a filtering structure that comprises(b) a harness that is joined to the mask body.2. The filtering face-piece respirator of claim 1 , wherein the mask body further comprises an outer mesh.3. The filtering face-piece respirator of claim 1 , wherein the staple fibers in the filtering structure are uncolored.4. The filtering face-piece respirator of claim 1 , wherein the melt-blown fibers are colored blue.5. The filtering face-piece respirator of claim 1 , wherein the melt-blown fibers are colored green or tan and the staple fibers are colored green or tan claim 1 , and wherein the melt-blown fibers and the staple fibers do not have the same color.6. The filtering face-piece respirator of claim 1 , further comprising an inner cover web and a shaping layer claim 1 , and wherein the filter layer contains melt-blown microfibers.7. The filtering face-piece respirator of claim 1 , wherein the outer cover web contains melt-blown microfibers.8. The filtering face-piece respirator of claim 1 , wherein the outer cover web contains at least about 30 weight percent staple fibers and 70 weight percent or less melt-blown fibers.9. The filtering face-piece respirator of claim 1 , wherein the outer cover web contains at least about 40 weight ...

FILTERING FACE-PIECE RESPIRATOR HAVING SUPPORT STRUCTURE INJECTION MOLDED TO FILTERING STRUCTURE

A filtering face-piece respirator that comprises a mask body and a harness . The mask body includes a supporting frame structure and a filtering structure . The frame structure is injection molded onto the filtering structure such that the frame structure becomes bonded to the filtering structure . 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. 1. A filtering face-piece respirator that comprises:a) a harness; and (i) a filtering structure; and', '(ii) a supporting frame structure that has been injection molded onto the filtering structure such that the filtering structure becomes bonded thereto., 'b) a mask body that comprises2. The filtering face-piece respirator of claim 1 , wherein the injection molded supporting frame structure and the filtering structure are bonded by at least one of mechanical interpenetration and chemical adhesion.3. The filtering face-piece respirator of claim 1 , wherein the injection molded supporting frame structure does not penetrate into a first major surface of the filtering structure so as to be visible from an opposing second major surface where the frame structure is bonded to the filtration structure.4. The filtering face-piece respirator of claim 3 , wherein there is a continuous bond at interfaces between the injected molded supporting frame structure and the filtering structure.5. The filtering face-piece respirator of claim 4 , wherein the filtering structure is compressed at the continuous bond by injection molding of the supporting frame structure thereto.6. The filtering face-piece respirator of claim 1 , wherein the supporting frame structure has a skeletal configuration that comprise members that have a cross-sectional area of 2 to 12 square millimeters.7. The filtering face-piece respirator of claim 2 , wherein the depth of mechanical interpenetration is at least partially ...

Respirator Having Elastic Straps Having Openwork Structure

Various embodiments of a respirator are disclosed. The respirator can include a mask body and one or more elastic straps that are secured to the mask body on opposing sides. The elastic straps can have an openwork construction and can include a netting that has an array of polymeric strands periodically joined together at bond regions throughout the array. In one or more embodiments, the openwork elastic straps are lighter and more breathable than conventional straps. This improvement in breathability can make the respirator more comfortable to wear. 1. A respirator that comprises:a mask body; anda harness that comprises one or more elastic straps that are joined to the mask body on opposing sides of thereof, the strap(s) comprising a netting that has an array of polymeric strands periodically joined together at bond regions throughout the array but do not substantially cross over each other.2. The respirator of claim 1 , wherein the strap(s) has a thickness up to 1 millimeter.3. The respirator of claim 1 , wherein at least one of the one or more strap(s) comprises first and second layers of the netting claim 1 , the first and second layers of the netting being secured to each other.4. The respirator of claim 3 , wherein at least one of the one or more strap(s) comprises first and second layers of the netting claim 3 , the first and second layers of the netting being secured directly to each other.5. The respirator of claim 4 , wherein the first netting layer has a first color that is different from a color of the second netting layer.6. The respirator of claim 5 , wherein the first and second netting layers are secured to one another such that the array of polymeric strands in each of the layers correspond to one another when viewed from a plane projected onto a major surface of the strap(s).7. The respirator of claim 1 , wherein the array of polymeric strands has open spaces that allow a person to see through the array.8. The respirator of claim 7 , wherein the ...

Respirator having elastic straps having openwork structure

Various embodiments of a respirator are disclosed. The respirator can include a mask body and one or more elastic straps that are secured to the mask body on opposing sides. The elastic straps can have an openwork construction and can include a netting that has an array of polymeric strands periodically joined together at bond regions throughout the array. In one or more embodiments, the openwork elastic straps are lighter and more breathable than conventional straps. This improvement in breathability can make the respirator more comfortable to wear.

Flat-fold filtering face-piece respirator having structural weld pattern

FLAT-FOLD FILTERING FACE-PIECE RESPIRATOR HAVING STRUCTURAL WELD PATTERN OF TIE INVENTION A flat-fold filtering face piece respirator 10 that comprises a mask body 12 that has 5 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 0 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. 3M 761307v1 24a 3, Fg 10 28a \* *1812 24b Fig.16 Fig. 2

Respirator having mottled appearance

A filtering face-piece respirator (10) that comprises a mask body (12) and a harness (14) that is attached to the mask body (12). The mask body (12) comprises a shaping layer (20) and a filtering structure (22) that contains a filtering layer (32). The filtering structure (22) also comprises an outer cover web (36b) that includes colored melt-blown fibers and staple fibers. The use of colored melt-blown fibers and staple fibers in an outer cover web provides the respirator with a mottled colored appearance -- that is, the color does not appear uniform over the outer surface of the outer cover web.

Splash-fluid resistant filtering face-piece respirator

A filtering face-piece respirator 10 that comprises a mask body 12 and a harness 14 that is joined to the mask body 12. The mask body 12 includes a filter layer 30 and a nonwoven fibrous cover web 16. The fibrous cover web 16 is partially occluded and is generally parallel to and spaced from the filter layer 30 such that air passing through the cover web 16 can move freely between the cover web 16 and the filter layer 30 so that it can enter the filter layer 30 at essentially any available point over the filter layer surface 32. The inventive respirator is beneficial in that it can provide very good splash fluid and airborne contaminant protection while also exhibiting an extraordinary low pressure drop across the mask body during breathing.

Splash-fluid resistant filtering face-piece respirator

A filtering face-piece respirator 10 that comprises a mask body 12 and a harness 14 that is joined to the mask body 12. The mask body 12 includes a filter layer 30 and a nonwoven fibrous cover web 16. The fibrous cover web 16 is partially occluded and is generally parallel to and spaced from the filter layer 30 such that air passing through the cover web 16 can move freely between the cover web 16 and the filter layer 30 so that it can enter the filter layer 30 at essentially any available point over the filter layer surface 32. The inventive respirator is beneficial in that it can provide very good splash fluid and airborne contaminant protection while also exhibiting an extraordinary low pressure drop across the mask body during breathing.

Molded respirator having outer cover web joined to mesh

A respirator 10 that has a mask body 12 and a harness 14 that is attached to the mask body 12. The mask body 12 includes a filtering structure 18 that has an inner cover web 40a, an outer cover web 40b that comprises melt-blown fibers and staple fibers, and a filtration layer 42 that is located between the inner and outer cover webs 40a, 40b. The mask body 12 also has a mesh 20 that is joined to the outer cover web 40b. A respirator having this construction is more resistant to inward collapse of the filter media during breathing and is more aesthetically pleasing.

Molded respirator having outer cover web joined to mesh

A respirator 10 that has a mask body 12 and a harness 14 that is attached to the mask body 12. The mask body 12 includes a filtering structure 18 that has an inner cover web 40a, an outer cover web 40b that comprises melt-blown fibers and staple fibers, and a filtration layer 42 that is located between the inner and outer cover webs 40a, 40b. The mask body 12 also has a mesh 20 that is joined to the outer cover web 40b. A respirator having this construction is more resistant to inward collapse of the filter media during breathing and is more aesthetically pleasing.

Molded respirator having outer cover web joined to mesh

A respirator 10 that has a mask body 12 and a harness 14 that is attached to the mask body 12. The mask body 12 includes a filtering structure 18 that has an inner cover web 40a, an outer cover web 40b that comprises melt-blown fibers and staple fibers, and a filtration layer 42 that is located between the inner and outer cover webs 40a, 40b. The mask body 12 also has a mesh 20 that is joined to the outer cover web 40b. A respirator having this construction is more resistant to inward collapse of the filter media during breathing and is more aesthetically pleasing.

Respiratory mask