Respirators including adjustable straps and methods of forming the same

Abstract

Various embodiments of a filtering face-piece respirator and a method of forming such respirators are disclosed. The filtering face-piece respirator includes a mask body having a filtering structure and an attachment area disposed on the mask body, the attachment area including a connection portion and an aperture disposed in the connection portion. Two or more layers of the filtering structure are connected together to form the connection portion. The filtering face-piece respirator also includes an adjustable strap having a first end and a second end, wherein the first end of the strap passes through the aperture of the attachment area such that the strap is connected to the attachment area. The aperture mechanically retains the strap.

Description

[0001] This application is a divisional application of patent application No. 201980059585.5, filed on September 11, 2019, entitled "A respirator including an adjustable strip and a method for forming the same". Background Technology

[0002] Respirators are typically worn over a person's respiratory tract in at least one of two situations: (1) to prevent impurities or contaminants from entering the wearer's respiratory system; and (2) to protect other persons or objects from exposure to pathogens and other contaminants exhaled by the wearer. In the first situation, the respirator is worn in an environment where the air contains particles that may be harmful to the wearer, such as in an auto repair shop. In the second situation, the respirator is worn in an environment where there is a risk of contamination to other persons or objects, such as in an operating room or cleanroom.

[0003] Various respirators have been designed for use in one or both of these situations. Some of these respirators are classified as “filtering masks” because the mask body itself functions as a filtering mechanism. Unlike respirators that use a rubber or elastomer mask body with an attachable filter cartridge (see, for example, U.S. Patent RE39,493 to Yuschak et al.) or an insert-molded filter element (see, for example, U.S. Patent 4,790,306 to Braun), filtering mask respirators are designed so that the filter medium covers most of the mask body, eliminating the need to install or replace filter cartridges. These filtering mask respirators typically have one of two configurations: molded respirators and folding respirators.

[0004] Molded filtering face mask respirators typically comprise a thermally bonded nonwoven fiber mesh or perforated plastic mesh to provide the cup-shaped configuration to the mask body. Molded respirators tend to maintain the same shape during use and storage. Therefore, these respirators cannot be folded flat for storage and transport. Patents disclosing embodiments of molded filtering face mask respirators include U.S. Patent 7,131,442 to Kronzer et al., U.S. Patents 6,923,182 and 6,041,782 to Angadjivand et al., U.S. Patent 4,807,619 to Dyrud et al., and U.S. Patent 4,536,440 to Berg.

[0005] As the name suggests, a flat-folding respirator can be folded flat for transport and storage. Such respirators can be unfolded into a cup-shaped configuration for use. Examples of flat-folding respirators are described in the following U.S. patents: 6,484,722 and 6,568,392, granted to Bostock et al., and 6,394,090, granted to Chen. Some flat-folding respirators are designed with welded lines, seams, and folds to help maintain their cup-shaped configuration during use. Rigid components are also incorporated into the panel of the mask body. See, for example, U.S. Patent Publications 2001 / 0067700 and 2010 / 0154805, granted to Duffy et al., and U.S. Design Patent 659,821, granted to Spoo et al.

[0006] When folded flat for storage, flat-fold respirators have two general orientations. In one configuration—sometimes called a “horizontal” flat-fold respirator—the mask body is folded crosswise, giving it an upper and lower section. The second type of respirator is called a “vertical” flat-fold respirator because the main folds are vertically oriented when viewed from the front in the vertical position. Vertical flat-fold respirators have a left and a right section on opposite sides of the vertical fold or centerline of the mask body.

[0007] This type of filtering respirator typically comprises several different components that are connected or assembled together to form a single unit. These components may include straps or bands, an exhalation valve, a face seal, a nose clip, etc. For example, a face seal is added regularly because it provides a comfortable fit between the wearer's face and the respirator mask body for different body contours, and also accommodates dynamic changes that could cause a seal failure, such as when the wearer's face moves while the wearer is speaking.

[0008] A filtering respirator is typically held securely to the wearer's face by one or more straps. These straps are usually glued, welded, or sewn directly to the mask body. However, some filtering respirators use buckles to allow for adjustment of the strap length. These buckles can also be glued, welded, or sewn to the mask body. Summary of the Invention

[0009] Generally, this disclosure provides various embodiments of a respirator and methods of forming such a respirator. The respirator may include an attachment region disposed on a mask body of the respirator, wherein the attachment region includes a connecting portion and an orifice disposed in the connecting portion. The respirator may also include an adjustable strip. A first end of the strip may pass through the orifice of the attachment region, such that the strip is attached to the attachment region. In one or more embodiments, the orifice of the attachment region mechanically holds the strip. Additionally, in one or more embodiments, the attachment region may include a patch having a first end portion and a second end portion attached to the mask body. The patch may also include an unattached central portion located between the first end portion and the second end portion, the unattached central portion forming an orifice between the patch and the mask body. The first end of the adjustable strip may pass through the orifice formed by the patch, such that the strip is attached to the attachment region and mechanically held by the orifice.

[0010] In one aspect, this disclosure provides a filtering face mask respirator including a mask body having a filtering structure and an attachment region disposed on the mask body, the attachment region including a connecting portion and an orifice disposed in the connecting portion. Two or more layers of the filtering structure are joined together to form the connecting portion. The filtering face mask respirator further includes an adjustable strip having a first end and a second end, wherein the first end of the strip passes through the orifice of the attachment region, such that the strip is connected to the attachment region. The orifice mechanically holds the strip.

[0011] In another aspect, this disclosure provides a method for forming a respirator, the method comprising: providing an attachment region on a mask body of a filtering mask respirator. Providing the attachment region includes connecting two or more layers of a filtering structure of the mask body together to form a connecting portion, and providing an opening in the connecting portion of the attachment region.

[0012] In another aspect, this disclosure provides a filtering face mask respirator including a face mask body having a filtering structure and an attachment region disposed on the face mask body, the attachment region including a patch having a first end portion and a second end portion connected to the face mask body and an unattached central portion forming an opening between the patch and the face mask body.

[0013] In another aspect, this disclosure provides a method for manufacturing a flat-fold respirator. The method includes: forming a mask body blank; attaching a buckle patch strip to the mask body blank to form an opening between the buckle patch strip and the mask body blank; and passing an end of the strip through the opening such that the strip is attached to the mask body blank.

[0014] All headings provided in this article are for the convenience of the reader and should not be used to limit the meaning of any text following the heading, unless otherwise specified.

[0015] The term "comprising" and its variations are not intended to be limiting wherever they appear in the specification and claims. Such terms are to be understood as implying the inclusion of the stated steps or elements or groups of steps or elements, but not excluding any other steps or elements or groups of steps or elements.

[0016] In this application, terms such as “a,” “an,” “the,” and “the” are not intended to refer to a single entity, but rather to include a general category of specific examples that can be used for illustration. The terms “a,” “an,” “the,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of…” and “containing at least one of…” followed by a list refer to any one of the items in the list and any combination of two or more items in the list.

[0017] The phrases “at least one of…” and “containing at least one of…” followed by a list refer to any item in the list and any combination of two or more items in the list.

[0018] As used herein, the term “or” is generally used in its usual sense, including “and / or”, unless the context clearly indicates otherwise.

[0019] The term “and / or” means one or all of the listed elements, or any combination of two or more of the listed elements.

[0020] As used herein, with respect to the quantity being measured, the term “about” refers to a deviation in the quantity being measured that is commensurate with the object of the measurement and the accuracy of the measuring equipment used, as a technician who would have expected to perform the measurement with a certain degree of care. In this document, “at most” a number (e.g., at most 50) includes that number (e.g., 50).

[0021] In addition, in this article, the numerical range expressed by endpoints includes all numbers contained in the range as well as endpoint values ​​(e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0022] Furthermore, the suffixes “a” and “b” can be used throughout this specification to denote various left and right component / feature structures, respectively. However, in most relevant aspects, the component / feature structures indicated by the suffixes “a” and “b” are substantially identical or mirror images of each other. It should be understood that, unless otherwise stated, the description of each component / feature structure (e.g., the component / feature structure identified by the suffix “a”) also applies to the corresponding component / feature structure (e.g., the component / feature structure identified by the suffix “b”). Similarly, unless otherwise stated, the description of a component / feature structure without a suffix applies to both the corresponding left and right component / feature structures.

[0023] Glossary

[0024] The terms used in this document will have the meanings defined below:

[0025] "Permeable zone" refers to the area or zone of a respirator that allows air to travel from the external gas space to the internal gas space and vice versa;

[0026] "Clean air" means a certain volume of ambient air that has been filtered to remove at least a portion of the pollutants present in the atmospheric environment.

[0027] "Pollutants" means particulate matter (including dust, mist and smoke) and / or other substances that are not generally considered particulate matter (e.g., organic vapors, etc.) but may be suspended in the air;

[0028] "Across dimensions" refers to the dimension that extends laterally from one side to the other across the entire respirator when viewed from the front.

[0029] "Cup-shaped configuration" and its variations refer to any container shape that can fully cover the wearer's nose and mouth;

[0030] "Elastic" in the context of straps or ear loops means that the straps can be stretched by at least 100% and return to their original size substantially without causing damage to the straps.

[0031] "External gas space" refers to the ambient atmospheric gas space that exhaled air enters after passing through and leaving the mask body and / or exhalation valve;

[0032] "External surface" refers to the surface of the mask body that is exposed to the ambient atmospheric gas space when the mask body is on the wearer's face;

[0033] "Face seal" means one or more components located between the face mask body and the wearer's face at one or more locations where the face mask body will otherwise come into contact with the face;

[0034] "Filtering mask" means that the mask body itself is designed to filter the air passing through it; there is no independently identifiable filter cartridge or insert-shaped filter element attached to or molded into the mask body to achieve this purpose.

[0035] "Filter" or "Filter Layer" means one or more layers of breathable material suitable for the primary purpose of removing contaminants (such as particles) from an airflow passing through it;

[0036] "Filter media" refers to a breathable structure designed to remove pollutants from the air that passes through it;

[0037] "Filter structure" refers to a general air-permeable structure for filtering air.

[0038] "Flat-folding" means that the respirator can be folded flat for storage and unfolded for use.

[0039] "Band" refers to a combination of structures or components that help support the main body of the mask on the wearer's face;

[0040] "As a whole" means to be manufactured at the same time; that is, to be made as a single component, rather than two separately manufactured components that are subsequently joined together.

[0041] "Internal gas space" refers to the space between the mask body and the wearer's face;

[0042] "Internal surface" refers to the surface of the mask body that is closest to the wearer's face when the mask body is positioned on the wearer's face;

[0043] "Linked to" means directly or indirectly fixed;

[0044] "Boundary line" means crease, seam, weld line, adhesive line, stitch line, hinge line and / or any combination thereof;

[0045] "Mask body" refers to such a breathable structure that is designed to fit snugly above the wearer's nose and mouth and helps to define an internal gas space that is separate from the external gas space (including the seams and adhesive points that connect its layers to the components).

[0046] "Nose clip" refers to a mechanical device (not a nose foam) that is designed to be used on the mask body to improve the seal at least around the wearer's nose;

[0047] "Nose area" refers to the part of the mask that is located above the wearer's nose when wearing a respirator;

[0048] "Periphery" refers to the outer edge of the main body of the mask. When a person wears a respirator, this outer edge is generally positioned close to the wearer's face; "peripheral section" is a part of the periphery.

[0049] "Folds" refers to parts that are designed to be or folded onto themselves;

[0050] "Polymer" and "plastic" each mean a material that primarily comprises one or more polymers and may also include other components;

[0051] "Respirator" refers to an air filtration device worn by a person to provide the wearer with clean breathing air;

[0052] "Side" refers to the area on the mask body that is a certain distance away from the plane that divides the mask body vertically from the center when the mask body is oriented in a vertical position and viewed from the front.

[0053] "Sinus region" refers to the portion or area of ​​the nasal region and the main body of the mask located below the wearer's eyes and / or eye sockets when the respirator is worn in the appropriate configuration.

[0054] "Close fit" or "close fit" means providing a substantially airtight (or largely leak-proof) fit (between the mask body and the wearer's face);

[0055] "Horizontal extension" generally refers to extending along a horizontal dimension; and

[0056] "Vertical folding respirator" refers to a respirator in which the main folds are vertically oriented when the mask is viewed from the front in an upright position.

[0057] These and other aspects of this disclosure will become apparent from the following detailed description. However, in no way should the foregoing summary be construed as a limitation on the claimed subject matter, which is defined only by the appended claims, as may be amended during examination. Attached Figure Description

[0058] Reference is made throughout the specification to the accompanying drawings, wherein similar reference numerals denote similar elements, and wherein:

[0059] Figure 1 A schematic front view of one embodiment of the respirator.

[0060] Figure 2 for Figure 1 A schematic perspective view of a respirator.

[0061] Figure 3 for Figure 1 A schematic cross-sectional view of the filter structure of the respirator's mask body.

[0062] Figure 4 A perspective view as part of another implementation of the respirator.

[0063] Figure 5 for Figure 4 A schematic cross-sectional view of the attachment area of ​​the respirator.

[0064] Figure 6 This is a schematic perspective view of the implementation scheme for the attached area.

[0065] Figure 7 A schematic front perspective view of another embodiment of the respirator.

[0066] Figure 8 for Figure 7 A schematic right-side view of a portion of a respirator.

[0067] Figure 9 A schematic side view of another embodiment of the respirator.

[0068] Figure 10 for Figure 9 A schematic perspective view of the attachment area of ​​the respirator.

[0069] Figure 11 A schematic side view of another embodiment of the respirator.

[0070] Figure 12 A schematic side view of another embodiment of the respirator.

[0071] Figure 13 A schematic plan view of one embodiment of a method for forming a respirator. Detailed Implementation

[0072] Generally, this disclosure provides various embodiments of a respirator and methods of forming such a respirator. The respirator may include an attachment region disposed on a mask body of the respirator, wherein the attachment region includes a connecting portion and an orifice disposed in the connecting portion. The respirator may also include an adjustable strip. A first end of the strip may pass through the orifice of the attachment region, such that the strip is attached to the attachment region. In one or more embodiments, the orifice of the attachment region mechanically holds the strip. Additionally, in one or more embodiments, the attachment region may include a patch having a first end portion and a second end portion attached to the mask body. The patch may also include an unattached central portion located between the first end portion and the second end portion, the unattached central portion forming an orifice between the patch and the mask body. The first end of the adjustable strip may pass through the orifice formed by the patch, such that the strip is attached to the attachment region and mechanically held by the orifice.

[0073] Figures 1 to 3 Various schematic diagrams are shown for one embodiment of a respirator 10. The respirator 10 includes a mask body 12, which includes a filtering structure 14 and one or more attachment areas 16 disposed on the mask body. Figures 1 to 3 In the illustrated embodiment, the mask body 12 includes a right attachment region 16a and a left attachment region 16b (collectively referred to as attachment regions 16). As used herein, the terms "right" and "left" refer to portions or elements of the respirator 10 as observed by an observer when the wearer is wearing the respirator. The right attachment region 16a is located on the right side 34 of the mask body 12, and the left attachment region 16b is located on the left side 36 of the mask body 12. Each attachment region 16 includes a connecting portion 18 and an aperture 20 disposed in the connecting portion. Two or more layers of the filter structure 14 are joined together to form the connecting portion 18. The respirator 10 also includes a right adjustable strip 22a and a left adjustable strip 22b (collectively referred to as adjustable strip 22). Each adjustable strip 22 includes a first end 24 and a second end 26. The first end 24 of the strip 22 passes through the aperture 20 of the attachment region 16, such that the strip is connected to the attachment region. In one or more embodiments, the orifice 20 of each attachment region 16 mechanically holds the strip 22.

[0074] The respirator 10 may include any suitable respirator. In one or more embodiments, the respirator 10 is a filtering mask respirator. Any suitable filtering mask respirator may be used for the respirator 10. In one or more embodiments, the filtering mask respirator is a horizontally folding respirator. Additionally, in one or more embodiments, the filtering mask respirator is a vertically folding respirator. In one or more embodiments, the filtering mask respirator 10 is a three-panel respirator, as further described herein.

[0075] While filtering respirators have been shown in this disclosure, respirators may include conformal rubber-type masks with one or more filter cartridges attached thereto. See, for example, the following U.S. patents: RE 39,493, granted to Yuschak et al., and 7,650,884, granted to Flannigan et al. Alternatively, it may be a full-face respirator. See, for example, U.S. patent 8,067,110, granted to Rakow et al.; 7,594,510, granted to Betz et al.; and D421,118 and D378,610, granted to Reischel et al.

[0076] The respirator 10's mask body 12 may include any suitable mask body, through which inhaled air passes before entering the wearer's respiratory system. The mask body 12 can remove at least a portion of contaminants from the surrounding environment, allowing the wearer to breathe filtered air. Furthermore, the mask body 12 may take on a variety of different shapes and configurations and is generally adapted to fit snugly against or within a support structure that contacts the wearer's face. In one or more embodiments, when the mask body is in a position such as... Figures 1 to 2 When the mask body 12 is in the open configuration shown, it can be cup-shaped.

[0077] The mask body 12 may include a breathable area 54 and an impermeable area 56. The breathable area 54 of the mask body 12 includes one or more portions of a filter structure 14 and is adapted to allow air to pass through the filter structure between the external and internal spaces of the respirator 10. Compared to the breathable area 54, the impermeable area 56 includes one or more portions of the filter structure 14 and is adapted to make it difficult for air to pass through the filter structure between the external and internal spaces of the respirator 10.

[0078] The mask body 12 may be defined by a periphery 30. The periphery 30 may take any suitable shape or one or more. Additionally, in one or more embodiments, the periphery 30 may include one or more recessed portions, as further described, for example, in U.S. Patent Publication 2008 / 0271739 to Facer et al. Although not shown, the respirator 10 may also include any suitable face sealing material disposed along at least a portion of the periphery 30 of the mask body 12.

[0079] In one or more embodiments, the mask body 12 may further include one or more flanges or tabs 32. Figures 1 to 3 In the illustrated embodiment, the mask body 12 includes a right flange 32a and a left flange 32b (collectively referred to as flanges 32). Although shown as including two flanges 32, the mask body 12 may include any suitable number of flanges. Additionally, the flanges 32 may be attached to the mask body 12 at any suitable location. Figures 1 to 3 As shown, the right flange 32a extends from the right side 34 of the mask body 12 at the right dividing line 58. Figure 2 The left flange 32b extends from the left side 36 of the mask body at the left dividing line 60. The flange 32 may include any suitable flange. An exemplary flange is described, for example, in U.S. Patent D449,377 to Henderson et al.

[0080] Each flange 32 may be integral with the mask body 12. In one or more embodiments, one or more flanges 32 may be manufactured separately and then attached to the mask body 12 using any suitable one or more techniques. Additionally, one or more flanges 32 may include weld points or adhesive points disposed thereon to increase flange stiffness.

[0081] Additionally, the face mask body 12 may include one or more dividing lines 38, which may be formed using any suitable technique or combination thereof, such as folding, welding (e.g., ultrasonic welding), applying pressure (heated or unheated), adhesion, stitching, and combinations thereof. Furthermore, the dividing lines 38 may each be substantially continuous, discontinuous, straight, curved, and combinations thereof. In one or more embodiments, the dividing lines 38 may include weld lines or seams. The dividing lines 38 may be located on or within the face mask body 12 at any one or more suitable locations.

[0082] The respirator 10's mask body 12 may also include one or more additional dividing lines 40 (e.g., weld lines) disposed on the mask body or at any one or more suitable locations within the mask body. The one or more additional weld lines may take any one or more shapes and have any suitable dimensions. In one or more embodiments, the additional dividing lines (such as weld lines) may increase the structural stability of the mask body 12.

[0083] The mask body 12 may include any suitable filtering structure 14. For example, Figure 3 This is a schematic cross-sectional view of a portion of the filter structure 14. The filter structure 14, suitable for use with respirators according to this disclosure, can take many different shapes and configurations. For example... Figure 3 As shown, the filter structure 14 may have multiple layers, including a fiber filter layer 42 and one or more fibrous cover webs (e.g., an inner cover web 44 and an outer cover web 46). When the respirator 10 is a molded mask, the mask body 12 may also include an optional shaping layer 48, which may be located at any suitable location within the filter structure. See, for example, U.S. Patent 6,923,182 to Angadjivand et al.; 7,131,442 to Kronzer et al.; U.S. Patents 6,923,182 and 6,041,782 to Angadjivand et al.; U.S. Patent 4,807,619 to Dyrud et al.; and U.S. Patent 4,536,440 to Berg.

[0084] Generally, the filter structure 14 removes at least a portion of contaminants from ambient air and can also act as a barrier layer to prevent liquid splashes from entering the mask interior. The outer covering mesh 46 can be used to block or slow down any liquid splashes, and the inner filter structure can contain such splashes if they penetrate through other layers. The filter structure 14 can be a particulate filter or a gas and vapor filter. The filter structure 14 can include similar or different filter media and multiple layers of one or more covering meshes, depending on the application requirements. In one or more embodiments, the respirator 10 can include a fluid-impermeable mask body having one or more filter cartridges attached thereto. See, for example, U.S. Patent 6,874,499 to Viner et al., 6,277,178 and D613,850 to Holmquist-Brown et al., RE39,493 to Yuschak et al., D652,507, D471,627 and D467,656 to Mittelstadt et al., and D518,571 to Martin.

[0085] Covering fiber meshes 44, 46 may be located on the outer side of the filter structure 14 to trap any fibers that may detach from the filter structure. Typically, covering fiber meshes 44, 46 are made of selected fibers that provide comfort, particularly on the side 50 of the filter structure 14 that contacts the wearer's face. The construction of various filter layers, shaping layers, and covering fiber meshes that can be used with the filter structure used in the respirator of this disclosure is described in more detail herein.

[0086] The filter layers that can be advantageously used in the respirators of this disclosure generally have a low pressure drop (e.g., less than about 195 Pascals to 295 Pascals at a face velocity of 13.8 cm / s) to minimize the breathing work of the mask wearer. Additionally, the filter layers are flexible and have sufficient shear strength so that they substantially maintain their structure under the intended use conditions. Examples of particulate trapping filters include one or more webs of fine inorganic fibers (such as glass fibers) or polymeric synthetic fibers. The fiber webs of synthetic fibers may include electret-charged polymer microfibers prepared by processes such as melt blowing. Polyolefin microfibers formed from charged polypropylene provide specific utility for particulate trapping applications.

[0087] Typically, filter layer 42 is selected to achieve the desired filtration effect. Generally, filter layer 42 will remove a high percentage of particles and / or other contaminants from the airflow passing through it. For fiber filter layers, the fibers are selected depending on the type of substance to be filtered out, and the fibers are typically selected such that they do not stick together during the manufacturing process. As noted, filter layers can have a variety of shapes and forms and typically have a thickness of about 0.2 mm to 1 cm, more typically about 0.3 mm to 0.5 cm, and the filter layer can be a generally planar fiber web or can be corrugated to provide an expanded surface area. See, for example, U.S. Patents 5,804,295 and 5,656,368 to Braun et al. Filter layer 42 may also comprise multiple filter layers bonded together by adhesives or any other technology. Virtually any suitable material known (or later developed) for forming filter layers can be used as the filtration material. Meltblown fiber webs, such as those mentioned in Wente, Van A., Superfine Thermoplastic Fibers, Institution of Chemical Engineers, Vol. 48, p. 1342 and thereafter, 1956, are particularly useful when they are in the form of permanently charged (electrets) (see, for example, U.S. Patent 4,215,682 to Kubik et al.). These meltblown fibers can be microfibers with an effective fiber diameter of less than about 20 micrometers (µm) (referred to as “blow-molded microfibers”, or BMF for short), typically ranging from about 1µm to 12µm. The effective fiber diameter can be determined according to Davies, CN, “The Separation of Airborne Dust and Particles,” Institution of Mechanical Engineers, London, Proceedings 1B, 1952. BMF fiber webs containing fibers formed of polypropylene, poly(4-methyl-1-pentene), and combinations thereof are particularly preferred. Fibers of charged fibrillated membranes, as mentioned in U.S. Patent Re. 31,285 to van Turnhout, as well as rosin wool fiber webs and glass fiber or solution-blown fiber webs, or electrostatically sprayed fibers (especially in the form of microfibers), are also suitable.A charge can be applied to the fibers by contacting them with water, as disclosed in the following U.S. patents: 6,824,718 to Eitzman et al., 6,783,574 to Angadjivand et al., 6,743,464 to Insley et al., 6,454,986 and 6,406,657 to Eitzman et al., and 6,375,886 and 5,496,507 to Angadjivand et al. The fibers can also be charged by corona charging, as disclosed in U.S. Patent 4,588,537 to Klasse et al., or by triboelectric charging, as disclosed in U.S. Patent 4,798,850 to Brown. Additionally, additives can be included in the fibers to enhance the filtration performance of the fiber web prepared by the water-charging process (see U.S. Patent 5,908,598 to Rousseau et al.). Specifically, fluorine atoms can be disposed on the surface of the fibers in the filter layer to improve filtration performance in oil mist environments. See, for example, U.S. Patents 6,398,847B1, 6,397,458B1, and 6,409,806B1 granted to Jones et al. Typical basis weights of electret BMF filter layers are from about 10 g / m² to 100 g / m². When charged according to the technology described in, for example, Angadjivand et al.'s '507 patent, and when containing fluorine atoms as mentioned in Jones et al.'s patent, the basis weights can be from about 20 g / m² to 40 g / m² and from about 10 g / m² to 30 g / m², respectively. Additionally, adsorbent materials such as activated carbon can be disposed between the fibers and / or multiple layers comprising the filter structure. Furthermore, a separate particulate filter layer can be used in conjunction with the adsorbent layer to filter both particulates and vapors. The adsorbent component can be used to remove harmful or odorous gases from breathing air. Adsorbents may include powders or particulates bonded to the filter layer by adhesives, binders, or fibrous structures. See, for example, U.S. Patent 6,334,671 to Springett et al. and 3,971,373 to Braun. Adsorbent layers can be formed by coating a substrate such as fibers or mesh foam to create a thin, adhesive layer. Adsorbent materials may include chemically treated or untreated activated carbon, porous alumina-silica catalyst substrates, and alumina particles. Examples of adsorbent filtration structures that can conform to various configurations are described in U.S. Patent 6,391,429 to Senkus et al.

[0088] While typically not comparable to a filter layer, the covering fiber mesh 44, 46 can also have filtering capabilities and / or contribute to greater comfort when wearing a filtering respirator. The covering fiber mesh 44, 46 can be made of nonwoven fiber materials such as spunbond fibers containing, for example, polyolefins and polyesters. See, for example, U.S. Patent 6,041,782 to Angadjivand et al.; U.S. Patent 4,807,619 to Dyrud et al.; and U.S. Patent 4,536,440 to Berg. When the wearer inhales, air is drawn in through the mask body, and airborne particles are trapped in the gaps between the fibers (particularly the fibers in the filter layer).

[0089] The inner cover fiber mesh 44 can be used to provide a smooth surface for contact with the wearer's face. Additionally, besides providing splash protection, the outer cover fiber mesh 46 can be used to embed loose fibers within the mask body and for aesthetic purposes. The cover fiber meshes 44 and 46 generally do not provide any substantial filtering benefit to the filtering structure, but when placed outside (or upstream) the filtering layer, they can serve as a pre-filter. For a suitable level of comfort, the inner cover fiber mesh can have a relatively low basis weight and can be formed from relatively fine fibers. More specifically, in one or more embodiments, one or both of the cover fiber meshes 44 and 46 can be made to have a basis weight of about 5 g / m² to 70 g / m² (typically 10 g / m² to 30 g / m²), and the fibers can be less than 3.5 denier (typically less than 2 denier, more typically less than 1 denier, but greater than 0.1 denier). The average fiber diameter of the fibers used in covering fiber webs is often between about 5 micrometers and 24 micrometers, typically between about 7 micrometers and 18 micrometers, and more commonly between about 8 micrometers and 12 micrometers. The materials used in covering fiber webs may have a degree of elasticity (break elasticity is typically, but not necessarily, 100% to 200%) and may be plastically deformable.

[0090] Suitable materials for covering the fiber webs 44, 46 may be blown microfiber (BMF) materials, particularly polyolefin BMF materials, such as polypropylene BMF materials (including polypropylene blends, and also including blends of polypropylene and polyethylene). An exemplary process for preparing the BMF material covering the fiber web is described in U.S. Patent 4,013,816 to Sabee et al. The fiber web can be formed by collecting fibers on a smooth surface, typically a cylinder or rotating collector with a smooth surface. See, for example, U.S. Patent 6,492,286 to Berrigan et al. Spunbond fibers may also be used.

[0091] Typical cover fiber webs can be made of polypropylene or polypropylene / polyolefin blends containing 50% by weight or more polypropylene. These materials have been found to provide the wearer with a high degree of softness and comfort, and additionally, when the filter material is a polypropylene BMF material, it remains fixed to the filter material without the need for adhesives between layers. Suitable polyolefin materials for cover fiber webs may include, for example, single polypropylene, blends of two polypropylenes, blends of polypropylene and polyethylene, blends of polypropylene and poly(4-methyl-1-pentene), and / or blends of polypropylene and polybutene. One example of fibers used for cover fiber webs is a polypropylene BMF made from the polypropylene resin “Escorene 3505G” from Exxon Corporation, providing a basis weight of about 25 g / m² and a fiber fineness in the range of 0.2 to 3.1 (an average of about 0.8 measured over 100 fibers). Another suitable fiber is polypropylene / polyethylene BMF (prepared from a mixture containing 85% resin "Escorene 3505G" and 15% ethylene / α-olefin copolymer "Exact 4023", also from Exxon Corporation), which provides a basis weight of about 25 g / m² and an average fiber fineness of about 0.8. Suitable spunbond materials are available under the trade names "Corosoft Plus 20", "Corosoft Classic 20", and "Corovin PP S 14" from Corovin GmbH, Peine, Germany, and carded polypropylene / viscose fiber materials are available under the trade name "370 / 15" from JW Suominen OY, Nakila, Finland. Covered fiber webs typically have very few fibers protruding from the web surface after processing, thus having a smooth outer surface. Embodiments of covering fiber mesh that can be used in respirators of this disclosure are described, for example, in U.S. Patent 6,041,782 to Angadjivand, 6,123,077 to Bostock et al., and PCT Publication WO 96 / 28216A to Bostock.

[0092] In one or more embodiments, one or both of the inner covering fiber web 44 and the outer covering fiber web 46 may comprise a polymer mesh. Any suitable polymer mesh described herein may be used for one or both covering fiber webs. The mesh may be made of a variety of polymer materials. Suitable polymers for mesh formation are thermoplastic materials. Examples of thermoplastic polymers that may be used to form the polymer mesh of the present invention include polyolefins (e.g., polypropylene and polyethylene), polyethylene-vinyl acetate (EVA), polyvinyl chloride, polystyrene, nylon, polyesters (e.g., polyethylene terephthalate), and elastomeric polymers (e.g., ABA block copolymers, polyurethanes, polyolefin elastomers, polyurethane elastomers, metallocene polyolefin elastomers, polyamide elastomers, ethylene vinyl acetate elastomers, and polyester elastomers). Blends of two or more materials may also be used in the manufacture of the mesh. Examples of such blends include polypropylene / EVA and polyethylene / EVA. Polypropylene is preferably used for the polymer mesh because meltblown fibers are typically made of polypropylene. Using similar polymers enables the proper welding of the support structure to the filter structure.

[0093] The forming layer 48 may be made of at least one layer of fibrous material that can be heat-molded into a desired shape and retain its shape upon cooling. Shape retention is typically achieved by bonding the fibers together at their contact points, for example, by fusion or welding. Any suitable material known for preparing the shape-retaining layer of a direct-molded breathing mask can be used to form the mask shell, including, for example, a mixture of synthetic short fibers (e.g., crimped) and bicomponent short fibers. Bicomponent fibers are fibers comprising two or more distinct fibrous material regions, typically distinct polymer material regions. Typical bicomponent fibers include an adhesive component and a structural component. The adhesive component allows the fibers of the shape-retaining shell to bond together at fiber junctions during heating and cooling. During heating, the adhesive component flows to contact adjacent fibers. The shape-retaining layer may be prepared from a fiber mixture comprising short fibers and bicomponent fibers in weight percentages ranging from, for example, 0 / 100 to 75 / 25. In one or more embodiments, the material comprises at least 50% by weight of bicomponent fibers to create a greater number of junction bonding points, which in turn increases the shell's elasticity and shape retention.

[0094] Suitable bicomponent fibers 48 for use in the forming layer include, for example, side-by-side configurations, concentric skin-core configurations, and elliptical skin-core configurations. One suitable bicomponent fiber is a polyester bicomponent fiber from Kosa Corporation, Charlotte, NC, USA, under the trade name "KOSA T254" (12 denier, 38 mm in length), which can be used in combination with, for example, polyester staple fibers from Kosa under the trade name "T259" (3 denier, 38 mm in length), or with, for example, polyethylene terephthalate (PET) fibers from Kosa under the trade name "T295" (15 denier, 32 mm in length). Alternatively, the bicomponent fiber may comprise a generally concentric skin-core configuration having a crystalline PET core surrounded by a polymeric outer skin formed from isophthalate and terephthalate monomers. The latter polymer has a lower heat softening temperature than the core material. Polyester has the advantage of helping masks stay flexible and absorbing less moisture than other fibers.

[0095] In one or more embodiments, a forming layer 48 without bicomponent fibers can be prepared. For example, heat-flowing polyester fibers can be included in the forming layer along with, for example, short, crimped fibers, such that when the fiber web material is heated, the binder fibers melt and flow to the fiber junctions, where they clump together as the binder material cools, thereby creating adhesion at the junctions. Short fibers (for the forming component) pretreated with an ammonium polyphosphate-type expansive FR agent (in addition to or instead of a spraying agent) can also be used in conjunction with this disclosure. Containing the short fibers with an agent or otherwise treating the short fibers with an agent and then forming a shell (using binder fibers to hold them together) would be another approach to using the agent.

[0096] When using a fiber web as the material for the shape-retaining shell, the web can be conveniently prepared on a Rando Webber air-forming machine (from Rando Machine Corporation, Macedon, NY) or a carding machine. The web can be formed from bicomponent fibers or other fibers having conventional short fiber lengths suitable for such equipment. To obtain a shape-retaining layer with the desired elasticity and shape retention, the basis weight of the layer can be at least about 100 g / m², but lower basis weights are also possible. Higher basis weights, such as about 150 g / m² or more than 200 g / m², provide greater resistance to deformation and higher elasticity, and may be more suitable if the mask body is used to support the exhalation valve. When using these minimum basis weights in combination, the forming layer typically has a maximum density of about 0.2 g / m² in the central region of the mask. Typically, the forming layer will have a thickness of about 0.3 mm to 2.0 mm, more typically about 0.4 mm to 0.8 mm. Examples of the forming layers applicable to this disclosure are described, for example, in U.S. Patent 5,307,796 to Kronzer et al., U.S. Patent 4,807,619 to Dyrud et al., and U.S. Patent 4,536,440 to Berg. Short fibers (for the forming component) pretreated with an ammonium polyphosphate-type expanding FR agent (in addition to or instead of spraying the agent) may also be used in conjunction with this disclosure. Containing the short fibers with the agent or otherwise treating the short fibers with the agent and then forming a shell (using a binder fiber to hold them together) would be another approach to using the agent.

[0097] As mentioned herein, a flange 32 may be formed such that it is integral with the mask body 12, and may therefore include one or more layers and materials identical to the mask body. For example, one or both of the right flange 32a and the left flange 32b may include at least one of the following: an outer covering fiber web 46, a filter layer 42, a shaping layer 48, and an inner covering fiber web 44. In one or more embodiments, one or both of the right flange 32a and the left flange 32b may not include one or more of these layers.

[0098] The attachment area 16 is disposed on or within the mask body 12. The attachment area 16 may be disposed at any one or more suitable locations on or within the mask body 12. Additionally, the respirator 10 may include any suitable number of attachment areas 16. Figures 1 to 2As shown, the respirator 10 includes two attachment regions 16a and 16b respectively disposed on the right side 34 and left side 36 of the mask body 12. The right attachment region 16a may be the same as the left attachment region 16b. In one or more embodiments, the right attachment region 16a may be different from the left attachment region 16b. In one or more embodiments, the attachment region 16 includes or forms a buckle integral with the mask body 12.

[0099] exist Figures 1 to 2 In the illustrated embodiment, the right attachment region 16a is disposed on the right flange 32a, and the left attachment region 16b is disposed on the left flange 32b. In one or more embodiments, the attachment region 16 may be disposed on the mask body 12. Additionally, in one or more embodiments, the attachment region 16 may be disposed adjacent to the periphery 30 of the mask body 12.

[0100] Each attachment region 16 includes a connecting portion 18 and an aperture 20 disposed in the connecting portion. The connecting portion 18 can be formed using any suitable one or more techniques. In one or more embodiments, two or more layers of the filter structure 14 are joined together using any suitable one or more techniques to form the connecting portion 18. In one or more embodiments, two or more of the outer covering fiber web 46, filter layer 42, optional forming layer 48, and inner covering fiber web 44 can be joined together using any suitable one or more techniques, such as welding, ultrasonic welding, adhesion using any suitable adhesive, mechanically joined together using, for example, nails, stitching, and thermal and pressure bonding. The connecting portion 18 can take any shape and have any suitable size. In one or more embodiments, the entire surface area of ​​one or both flanges 32 can include the connecting portion 18. Additionally, the connecting portion 18 can have any suitable density. In one or more embodiments, the connecting portion 18 can have a density of at least 100 gsm. In one or more embodiments, the connecting portion 18 can have a density of no more than 600 gsm.

[0101] An opening 20 is provided in the connecting portion 18. The opening 20 may be provided at any suitable location on or through the connecting portion 18. Although shown as including one opening 20, the attachment area 16 may include any suitable number of openings, such as two, three, four, or more. Additionally, the opening 20 may take any suitable shape or have any suitable size. In one or more embodiments, the opening 20 does not extend into the ventilated area 54 of the mask body 12.

[0102] The orifice 20 may be adapted to mechanically retain the strip 22 using any suitable one or more techniques. In one or more embodiments, the perimeter of the orifice 20 of the attachment region 16 may be smaller than the outer perimeter of the strip 22, such that the strip is mechanically retained by the orifice. Additionally, in one or more embodiments, the orifice 20 may include a gripping portion adapted to adjustably retain the strip 22 within the orifice, as further described herein.

[0103] An adjustable strip 22 is attached to one or both attachment regions 16 of the mask body 12. The strip 22 includes a first end 24 and a second end 26. The first end 24 passes through an opening 20 in the attachment region 16, such that the strip is connected to the attachment region. In one or more embodiments, the second end 26 of the strip 22 can be attached to the mask body 12 at any suitable location using any suitable technique or method. In one or more embodiments, the second end 26 of the strip 22 can be attached to the attachment region 16 on the same side of the mask body 12 as the side through which the first end 24 of the strip passes through the opening 20, or on the opposite side of the mask body. For example, as... Figure 2 As shown, the right strip 22a includes a first end 24a of an aperture 20a passing through the right attachment region 16a. A second end 26a of the right strip 22a is connected to the mask body 12 adjacent to the periphery 30. As used herein, the term "adjacent to the periphery" means that an element or component is positioned closer to the periphery 30 than to the central region 52 of the mask body 12. In one or more embodiments, the first end 24a of the right strip 22a may be connected to the right attachment region 16a, and the second end 26a of the right strip may be connected to the left side 36 of the mask body 12. Similarly, the first end 24b of the left strip 20b may be connected to the left attachment region 16b, and the second end 26b of the left strip may be connected to the left side 36 of the mask body adjacent to the periphery 30. In one or more embodiments, the second end 26b of the left strip 22b may be connected to the right side 34 of the mask body 12.

[0104] In one or more embodiments, at least one strip 22 may comprise one or more elastic materials such that it can expand to more than twice its total length and can return to its relaxed state multiple times throughout the entire service life of the respirator. One or both strips 22 may also increase to three or four times their relaxed length and return to their original state without any damage when the tension is removed. In one or more embodiments, the elastic limit is therefore not less than two, three, or four times the relaxed length of the strip 22. The strip 22 may comprise any suitable material or combination of materials.

[0105] Typically, each strip 22 may be approximately 10 cm to 35 cm long, 3 mm to 20 mm wide, and approximately 0.3 mm to 1 mm thick. Each strip 22 may be continuous, or the strip may have multiple components that can be connected together by other fasteners or buckles. For example, each strip 22 may have a first component and a second component connected together by fasteners that the wearer can quickly unfasten when removing the mask body 12 from the face. In one or more embodiments, each strip 22 may form a loop placed around the wearer's head. Examples of fastening or clamping mechanisms that can be used to connect one or more components of the strip together are shown, for example, in U.S. Patent 6,062,221 to Brostrom et al., 5,237,986 to Seppalla, and EP Patent Publication 1,495,785A1 to Chen.

[0106] The respirator 10 can be formed using any suitable one or more techniques. In one or more embodiments, the attachment region 16 is provided on the mask body 12 of the respirator 10 by joining two or more layers of the filter structure 14 of the mask body together to form a connection portion 18. An orifice 20 is provided in the connection portion 18 of the attachment region 16 using any suitable one or more techniques (e.g., cutting, trimming, laser cutting, drilling, laser ablation, die-cutting, etc.). In one or more embodiments, a first end 24 of the adjustable strip 22 can pass through the orifice 20 of the attachment region 16, such that the strip is attached to the attachment region and the orifice mechanically holds the strip.

[0107] As mentioned herein, the attachment region 16 may include any suitable number of apertures 20 disposed in the connection portion 18. For example, Figures 4 to 5 Various schematic diagrams are shown for another embodiment of the respirator 100. (With) Figures 1 to 3 All design considerations and possibilities related to the respirator 10 also apply to Figures 4 to 5 100 respirators. Figures 4 to 5 100 respirators and Figures 1 to 3 One difference between the respirators 10 is that the attachment region 116 includes a connecting portion 118 and three orifices 120 disposed in the connecting portion. One or more of the orifices 120 may be adapted to mechanically retain the strip 122 using any suitable one or more techniques. For example, in one or more embodiments, a first end 124 of the strip 122 may pass through one or more of the orifices 120, such that the strip is mechanically retained by the attachment region 116.

[0108] For example, Figure 5 for Figure 4A schematic cross-sectional view of a portion of the attachment region 116 of the respirator 100. A first end 124 of the strip 122 passes through a first orifice 126 from the bottom surface 102 of the connecting portion 118. The first end 124 then passes through a second orifice 128 from the top surface 104 of the connecting portion 118. Furthermore, the first end 124 then passes through a third orifice 130 from the bottom surface 102 of the connecting portion 118. The orifices 126, 128, and 130 are adapted to mechanically retain the strip 122.

[0109] Any suitable technique or one or more can be used to mechanically retain the strip at the orifice of the attachment region. For example, Figure 6 This is a schematic perspective view of another embodiment of attachment region 216. Figures 1 to 3 The attachment area 16 of the respirator 10 and Figures 4 to 5 All design considerations and possibilities relating to the attachment area 116 of the respirator 100 also apply to Figure 6 The attachment region 216. The attachment region 216 can be used with any suitable respirator (e.g., Figures 1 to 3 Used together with respirator 10.

[0110] The attachment area 216 includes a storage portion 218. A first opening 220 and a second opening 221 are provided in the connection portion 218. Each of the first opening 220 and the second opening 221 may take any one or more suitable shapes. Figure 6 As shown, the first aperture 220 includes a slit-shaped aperture, and the second aperture 221 is formed such that it forms a flap 202 disposed in the connecting portion 218. The flap 202 has a first end 204 that forms a movable hinge with the connecting portion 218. The second aperture 221 also includes a gripping portion 206 located at a second end 208 of the flap 202. The gripping portion 206 is adapted to mechanically hold the strip 222. For example, as Figure 6 As shown, the gripping portion 206 includes one or more teeth 210 that engage the strip 222 and prevent the strip from being pulled back through the second aperture 221 and the first aperture 220. The gripping portion 206 may include any suitable number of teeth or any other shape adapted to mechanically retain the strip 222. For example, in one or more embodiments, the gripping portion 206 may include a single tooth that mechanically engages the strip 222. Additionally, in one or more embodiments, the gripping portion 206 may include a groove for gripping the strip 222. Furthermore, the attachment region 216 may include a single aperture, such as aperture 221, through which the strip 222 passes and is mechanically retained by the gripping portion 206. To attach the strip 222 to the attachment region 216, a first end 224 of the strip passes through the first aperture and then through the second aperture 221, such that the strip is retained by the gripping portion 206.

[0111] As mentioned herein, one or more attachment areas may be located on the respirator mask body or anywhere suitable within the mask body. For example, Figures 7 to 8 Various schematic diagrams are shown for another embodiment of the respirator 300. (With) Figures 1 to 3 Respirator 10 and Figure 4 All design considerations and possibilities related to the respirator 100 also apply to Figures 7 to 8 The respirator 300 includes a three-panel mask body 312, which includes a central panel 302 and a top panel and a bottom panel (not shown) connected to the central panel. Any suitable three-panel respirator can be used, such as the respirator described in U.S. Patents 6,568,392 and 6,484,722 to Bostock et al.

[0112] The center panel 302 includes a right tab 304a and a left tab 304b. A right attachment region 316a is disposed on the right tab 304a, and a left attachment region 316b is disposed on the left tab 304b. The right attachment region 316a and the left attachment region 316b (collectively referred to as attachment regions 316) may include any suitable one or more attachment regions described herein. Each attachment region 316 includes a connection portion 318 and an aperture 320. The aperture 320 may be formed using any suitable one or more techniques. Figures 7 to 8 As shown in the embodiment, orifice 320 is formed by a first linear weld 306 and a second linear weld 308. One or more slits 307 may be provided in one or both of the first linear weld 306 and the second linear weld 308 to provide an opening defining orifice 320. The first linear weld 306 and the second linear weld 308 form orifice 320 such that the first end 324 of strip 322 can pass through orifice 320 of right attachment region 316a using any suitable one or more techniques. Figures 7 to 8 As shown, the first end 324 of the strip 322 passes through the orifice 320 of the right attachment region 316a, such that the orifice mechanically holds the strip 322.

[0113] Figures 7 to 8 300 respirators and Figures 1 to 3One difference between the respirators 10 is that the second end 326 of the strip 322 is connected to the left attachment region 316b by passing the second end through the orifice 320 of the left attachment region. Another difference is that the respirator 300 may include a second right attachment region 328a disposed on the right flap 304a and a second left attachment region 328b disposed on the left flap 304b. The second right attachment region 328a and the second left attachment region 328b may include any suitable attachment region. Although not shown, any suitable one or more techniques may be used to connect the second strip to the second right attachment region 328a and the second left attachment region 328b.

[0114] As mentioned herein, one or more attachment areas can be positioned on or within the mask body of the respirator using any suitable technique or one or more of these methods. For example, Figures 9 to 10 Various schematic diagrams are shown for another embodiment of the respirator 400. (With) Figures 1 to 3 Respirator 10 and Figure 3 All design considerations and possibilities related to the respirator 100 also apply to Figures 9 to 10 The respirator 400 includes a mask body 412, which includes a filter structure 414. A first attachment region 418 and a second attachment region 470 are disposed on the mask body 412 using any suitable one or more techniques. Although shown as including a first attachment region 418 and a second attachment region 470 disposed on the left side 436 of the mask body 412, the respirator 400 may include an additional attachment region disposed on the right side (not shown) of the mask body. For example, a first strap 402 may be attached to the left side 436 of the mask body 412, and a second strap (also not shown) may be attached to the right side of the mask body using the same one or more techniques for attaching the first strap 402 to the mask body.

[0115] Attachment areas 418 and 470 may include any suitable attachment area. Figures 9 to 10 In the illustrated embodiment, the first attachment region 418 includes a patch 420, and the second attachment region 470 includes a patch 472. Patch 420 includes a first end portion 422 and a second end portion 424, and patch 472 of the second attachment region 470 also includes a first end portion 474 and a second end portion 476. The first and second end portions of each of patches 422 and 472 are attached to the mask body 412 using any suitable technique or one or more. Each of the unattached center portion 426 of patch 420 and the unattached center portion 477 of patch 472 forms an opening 428, 480 between the respective patch and the mask body 412.

[0116] The respirator 400 also includes an adjustable strip 402, which includes a first end 404 and a second end 406. The first end 404 of the strip 402 passes through an aperture 428 of the patch 420 such that the strip is connected to an attachment region 418 when the aperture mechanically holds the strip. Additionally, the second end 406 of the strip 402 passes through an aperture 480 of the patch 472 such that the strip is connected to a second attachment region 470 when the aperture mechanically holds the strip.

[0117] The first attachment region 418 and the second attachment region 470 may be disposed at any suitable location on the mask body 412. In one or more embodiments, one or both of the first attachment region 418 and the second attachment region 470 may be disposed adjacent to the periphery 430 of the mask body. Alternatively, in one or more embodiments, one or both of the first attachment region 418 and the second attachment region 470 may be disposed outside the breathable area 482 of the mask body 412, such that the attachment regions do not obstruct one or more portions of the breathable area.

[0118] Patches 420 and 472 may comprise any suitable one or more materials, such as spunbond polypropylene (SBPP), nonwoven materials with a typical basis weight of, for example, 80 gsm-200 gsm, plastic sheets or films, non-injection molded plastic materials, and other plastic materials. In one or more embodiments, one or both of patches 420 and 472 may comprise nonwoven materials. Patches 420 and 472 may take any suitable one or more shapes and have any suitable dimensions. Additionally, patches 420 and 472 may be attached to the mask body 412 using any suitable one or more techniques, such as adhesion, mechanical fastening, welding, ultrasonic welding, etc. In one or more embodiments, one or both of patches 420 and 472 may be welded to the mask body 412. In one or more embodiments, one or both of patches 420 and 472 may be mechanically attached to the mask body using, for example, fasteners.

[0119] Figure 10 An enlarged view of a portion of the respirator 400, showing the attachment area 418 disposed on the mask body 412. (As shown in...) Figure 10As can be seen, the first end 404 of the strip 402 passes through an aperture 428 formed by the unattached center portion 426 of the patch 420. In one or more embodiments, the patch 420 may include a gripping portion adapted to mechanically retain the strip 402. For example, in one or more embodiments, the patch 420 may include a textured surface disposed on the inner surface of the unattached center portion 426, such that the textured surface mechanically retains the strip within the aperture 428. Additionally, in one or more embodiments, a slit or notch 429 may be formed in the unattached center portion 426, such that the strip 402 engages the slit and mechanically retains the strip. The slit 429 may take any suitable shape and have any suitable size. Furthermore, the slit 429 may be disposed at any suitable location on the patch 420.

[0120] Patches 420 and 472 can be discrete patches or continuous patches forming two or more openings between the patch and the mask body 412. For example, Figure 11 A schematic side view of another embodiment of the respirator 500. (Regarding...) Figures 9 to 10 All the design considerations and possibilities of the respirator 400 also apply to Figure 11 The respirator 500 includes a mask body 512 having a filter structure 514, a first attachment region 518 and a second attachment region 570 disposed on the left side 536 of the mask body. Although shown as including the first attachment region 518 and the second attachment region 570 disposed on the left side 536 of the mask body 512, the respirator 500 may also include an additional attachment region disposed on the right side (not shown) of the mask body.

[0121] The first attachment region 518 and the second attachment region 570 include a patch 520, which includes a first end portion 522 and a second end portion 524 connected to the mask body 512. The patch 520 also includes an attachment center portion 526 that is also connected to the mask body 512. Additionally, the patch 520 includes a first unattached portion 528 and a second unattached portion 530. The first unattached portion 528 is disposed between the first end portion 522 and the attachment center portion 526, and the second unattached portion 530 is disposed between the attachment center portion and the second end portion 524. The first unattached portion 528 forms a first opening 532, and the second unattached portion 530 forms a second opening 534.

[0122] The first aperture 532 and the second aperture 534 can be formed using any suitable technique or one or more. For example, in one or more embodiments, one or more ultrasonic welds 538 can be formed in the patch 520 in any suitable pattern to provide the first aperture 532 and the second aperture 534. Figure 11As shown, the ultrasonic weld 538 includes a parallel line in the portion adjacent to the orifice that connects the patch 520 to the mask body 512.

[0123] The respirator 500 also includes an adjustable strip 502 connected to a first attachment region 518 and a second attachment region 570, such that the first orifice 532 and the second orifice 534 mechanically hold the strip in place. Figure 11 As shown, strip 502 is a continuous strip passing through the first orifice 532 and the second orifice 534 using any suitable one or more techniques. In one or more embodiments, strip 502 may be disposed on the mask body 512 of respirator 500, and patch 520 may be disposed on the mask body and over a portion of strip, such that strip is disposed between patch and mask body, as shown. Figure 11 As shown in the diagram. The first end portion 522, the central portion 526, and the second end portion 524 can be attached to the mask body 512 using any suitable one or more techniques. By pulling the second end portion 504 of the strip 502 in the direction indicated by arrow 501, the respirator is pulled to fit snugly against the wearer's face, thus allowing the respirator 500 to fit tightly against the wearer's face.

[0124] The strips of the various embodiments of the respirator described herein can be attached to the respirator's mask body using any suitable one or more techniques. For example, Figure 12 A schematic side view of another embodiment of the respirator 600. Figure 11 All design considerations and possibilities related to the respirator 500 also apply to Figure 12 The respirator is 600. (For example...) Figure 12 As shown, the respirator 600 includes a mask body 612 having a filtering structure 614. The respirator 600 also includes a first attachment region 618 and a second attachment region 670 disposed on the mask body 612. The first attachment region 618 and the second attachment region 670 include a patch 620. The patch 620 includes a first end portion 622 and a second end portion 624. Each of the first end portion 622 and the second end portion 624 is attached to the mask body 612. Additionally, the patch 620 includes an attachment center region 626 disposed between the first end portion 622 and the second end portion 624. The attachment center portion 626 is attached to the mask body 612 using any suitable one or more technologies. The patch 620 also includes a first unattached portion 628 and a second unattached portion 630. The first unattached portion 628 forms a first opening 632, and the second unattached portion 630 forms a second opening 634.

[0125] The respirator 600 also includes an adjustable strip 602 connected to a first attachment region 618 and a second attachment region 670, such that a first orifice 632 and a second orifice 634 mechanically hold the strip in place. The strip 602 includes a tab 604 disposed on a first end 606 of the strip. Furthermore, the strip 622 includes a second end 608 connected to the attachment region 670 via a patch 620.

[0126] To adjust the length of the strip 602, the wearer or assistant can pull the tab 604 of the strip along direction 601, causing the strip to shorten and the mask body 612 to be pulled close to the wearer's face. In one or more embodiments, the second end of the strip 608 may pass through the second opening 634 and may also include a tab (not shown) such that the tab on the second end of the strip can also be pulled toward the wearer's face to further tighten the strip. The second end 608 of the strip 602 can be attached to the mask body 612 using any suitable one or more techniques. In one or more embodiments, the second end 608 of the strip 602 is mechanically held within the opening 634 by a patch 620.

[0127] Figure 11 500 respirators and Figure 12 The respirator 600 can be manufactured using any suitable technology or one or more techniques. For example, Figure 13 To form Figure 11 A schematic plan view of one embodiment of the respirator 500 method 700. (Although referenced...) Figure 11 The respirator 500 is described, but method 700 can be used to form any suitable respirator.

[0128] Method 700 includes forming a face mask body blank 701 using any suitable one or more techniques. A fastening patch strip 704 can be attached to the face mask body blank 701 using any suitable one or more techniques. In one or more embodiments, the fastening patch strip 704 can be attached to multiple face mask body blanks 701 simultaneously using any suitable one or more techniques. In one or more embodiments, the fastening patch strip 704 can be applied along the longitudinal direction of a continuous process.

[0129] The buckle patch strip 704 can be attached to the face mask body blank 701 using any suitable one or more techniques to form one or more orifices 532, 534 between the buckle patch strip and the face mask body blank. As mentioned herein, one or more ultrasonic welds 538 can be formed between the buckle patch strip 704 and the face mask body blank 701 to form the first orifice 532 and the second orifice 534. In one or more embodiments, a second buckle patch strip 706 can also be attached to the face mask body blank 701 to form one or more additional attachment areas. The buckle patch strip 704 can be trimmed between face mask body blanks 701 to provide a buckle patch 520, such as... Figure 11 As shown in the diagram. Additionally, although not shown, strip 502 may pass through one or more openings 532, 534, such that the strip is connected to the mask body blank 701. Furthermore, each mask body blank 701 may be folded and joined together to form the mask body 512 using any suitable one or more techniques (e.g., one or more techniques described in U.S. Patents 6,484,722 and 6,568,392 to Bostock et al.), as... Figure 11 As shown in the diagram. In one or more embodiments, the strip 502 may be attached to one or both of the attachment regions 518, 570 before or after the mask body blank 701 is formed into the mask body 512.

[0130] All references and publications cited herein are expressly incorporated in their entirety by reference, except where they may directly conflict with this disclosure. Exemplary embodiments of this disclosure have been discussed, and possible variations within the scope of this disclosure have been mentioned. These and other variations and modifications in this disclosure will be apparent to those skilled in the art without departing from the scope of this disclosure, and it should be understood that this disclosure is not limited to the exemplary embodiments set forth herein. Therefore, this disclosure is limited only to the claims provided below.

Claims

1. A filtering face mask respirator, the filtering face mask respirator comprising: The face mask body includes a filter structure, which includes one or more layers of filter media and one or more layers of covering fiber mesh. A flange extending from the periphery of the mask body; A first attachment area is provided on the filter structure, the first attachment area is located on the flange and outside the breathable area of ​​the mask body, the first attachment area includes a first linear weld and a second linear weld in the filter structure defining at least one elongated orifice. as well as A first adjustable strip passes through the at least one elongated orifice in the first attachment region, such that a welding edge adjacent to the at least one elongated orifice includes a gripping portion that adjustably retains the first adjustable strip within the at least one elongated orifice in a frictional manner.

2. The filter-type face mask respirator according to claim 1, wherein the face mask body includes a flange, and wherein the first attachment region is disposed on the flange.

3. The filter-type respirator according to claim 1, wherein one or more orifices do not extend into the breathable area of ​​the mask body.

4. The filter-type face mask respirator according to claim 1, wherein the circumference of the one or more orifices in the first attachment region is smaller than the circumference of the first adjustable strip.

5. The filtering respirator of claim 1, wherein the first attachment area includes a buckle integral with the mask body.

6. The filter-type respirator of claim 1, wherein the first adjustable strip includes a first end and a second end, wherein the first end of the first adjustable strip passes through the one or more openings of the first attachment region, and the second end of the first adjustable strip is attached to the mask body.

7. The filter-type respirator of claim 1, comprising a second attachment region disposed on the filter structure adjacent to the periphery of the mask body, and including one or more orifices in the filter structure, wherein a first adjustable strip passes through the one or more orifices of the second attachment region such that the one or more orifices of the second attachment region include a second gripping portion that adjustably holds the first adjustable strip.

8. The filter-type face mask respirator according to claim 7, wherein the face mask body includes a flange, wherein the first attachment region and the second attachment region are disposed on the flange.

9. The filter-type respirator of claim 7, wherein one or more orifices do not extend into the breathable area of ​​the mask body.

10. The filter-type face mask respirator of claim 7, wherein the circumference of the one or more orifices of the first attachment region and the second attachment region is smaller than the circumference of the first adjustable strip.

11. The filtering face mask respirator according to claim 1, comprising: A second attachment region, disposed on the filter structure, adjacent to the periphery of the mask body, and including one or more openings in the filter structure, and A second adjustable strip passes through the one or more orifices of the second attachment region such that the one or more orifices of the second attachment region include a second gripping portion that adjustably holds the second adjustable strip.

12. The filter-type face mask respirator according to claim 11, wherein the face mask body includes a flange, wherein the first attachment region and the second attachment region are disposed on the flange.

13. The filter-type respirator of claim 11, wherein one or more orifices do not extend into the breathable area of ​​the mask body.

14. The filter-type face mask respirator of claim 11, wherein the perimeter of the one or more orifices of the first attachment region and the second attachment region is less than the perimeter of the first adjustable strip and the perimeter of the second adjustable strip.

15. The filtering face mask respirator according to claim 11, wherein the first adjustable strip and the second adjustable strip each include a first end and a second end, wherein: The first end of the first adjustable strip passes through one or more openings in the first attachment area, and the second end of the first adjustable strip is attached to the mask body; and The first end of the second adjustable strip passes through the one or more openings in the second attachment area, and the second end of the second adjustable strip is attached to the mask body.

16. The filter-type face mask respirator of claim 15, wherein the face mask body includes a flange, wherein the first attachment region and the second attachment region are disposed on the flange.

17. The filter-type respirator of claim 15, wherein one or more orifices do not extend into the breathable area of ​​the mask body.

18. The filter-type respirator of claim 15, wherein the perimeter of the one or more orifices of the first attachment region and the second attachment region is less than the perimeter of the first adjustable strip and the perimeter of the second adjustable strip.

19. A method of forming a filtering face mask respirator, the method comprising: A first attachment area is provided on the mask body of a filtering respirator, wherein providing the first attachment area includes: On the flange and outside the breathable area, two or more layers of the filter structure of the mask body are welded together along the first linear weld and the second linear weld to form a connecting portion, and at least one elongated orifice is provided in the connecting portion by opening a slit between the first linear weld and the second linear weld. The first adjustable strip is passed through the at least one elongated orifice of the first attachment region such that the welding edge adjacent to the at least one elongated orifice includes a gripping portion that adjustably retains the first adjustable strip within the at least one elongated orifice in a frictional manner.

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