BRPI1010461A2 - filter facepiece respirator and method of producing a filter facepiece respirator - Google Patents

Abstract

FILTERING FACIAL PART RESPIRATOR AND METHOD OF PRODUCTION OF A FILTERING FACIAL PART RESPIRATOR. A filtration facepiece respirator 10 having a harness 14, a mask body 12, and the first and second flanges 30a, 30b. The mask body 12 comprises a filtering structure 16 and has a gripping feature, such as the first and second flanges 30a, 30b disposed on the first and second sides of the mask body. The first and second marking areas 32a, 32b are positioned on the first and second flanges 30a, 30b, respectively. Providing marking areas on a mask body respirator's hold feature is beneficial in informing the wearer of where to attach the mask body for wearing, undressing and adjusting.

Description

"FILTERING FACIAL PART RESPIRATOR AND METHOD OF PRODUCTION OF A FILTERING FACIAL PART RESPIRATOR" Field of the Invention

The present invention relates to a respirator having a grip feature located on the mask body. The gripping feature includes marking areas that provide an indication of where the wearer should attach the mask body for wearing, or undressing, or adjusting.

Background

Respirators are commonly used over a person's breathing passages for at least one of two common purposes: (1) to prevent impurities or contaminants from entering the user's breathing path; and (2) protect other persons or things from exposure to pathogens and other contaminants exhaled by the user. In the first situation, the respirator is used in an environment where air contains particles that are harmful to the user, for example in an auto parts store. In the second situation, the respirator is used in an environment where there is a risk of contamination to other people or things, for example, in an operating room or a room.

clean. !

A variety of respirators have been designed to meet

one (or both) of these purposes. Some respirators have been categorized as "facepieces for filtration" due to the fact that the mask body itself functions as the filtration mechanism. Unlike respirators that use elastomeric or rubber masks in conjunction with affixable filter cartridges (see, for example, Dolby US Patent 4,098,270) or injection molded filter elements (see, for example, US 4,790). (Braun 306), filtration facepiece respirators are designed to cause filter media to cover a large part of the entire mask body so that there is no need to install or replace a filter cartridge. Filtration facepiece respirators are commonly presented in one of two configurations: molded respirators and flat bend respirators.

Molded filtration facepiece respirators regularly comprise thermally bonded nonwoven webs or open-seamed plastic nets to provide the mask body with its cup-shaped configuration. Molded respirators tend to keep the same shape during use and storage. Examples of patents having molded filtration facepiece respirators include US Patent 7,131,442 to Kronzer et al, 6,923,182, 6,041,782 to Angadjivand et al., 4,850,347 to Skov, 4,807,619 to Dyrud et al. al., 4,536,440 to Berg, and Des. 285,374 to Huber et al.

Flat-breather respirators - as their name implies - can be folded flat for shipping and storage and can be opened in a cup-shaped configuration for use. U.S. Patent Nos. 6,568,392 and 6,484,722 to Bostock et al. And 6,394,090 to Chen disclose examples of flat bend respirators.

Before wearing a respirator, it is of utmost importance that the respirator wearer read and understand the instructions for use. User strangeness about, for example, flat-breather respirators can lead to mishandling and errors in dressing and taking. Such misuse may result in improper and unjust fitting, which may lead to a lack of protection and may also degrade a user's perception of respirators.

Some filtration facepiece respirators have been provided

of hold features to assist the user to wear and remove. U.S. Patent Nos. 6,948,499 and 6,945,249 to Griesbach, Ili et al. present an example of such a filtering facepiece respirator. While this PE respirator is provided with a "flap" grip feature, the grip feature does not include any kind of marking areas that would intuitively inform the user of where to hold the mask during dressing, removing and adjusting operations. . Therefore, the grip feature may not be readily apparent and, accordingly, may not be used by the user. As discussed below, the present invention, however, provides a user-friendly way to quickly identify where to hold the mask for fit purposes.

Summary of the Invention The present invention provides a novel facepiece respirator

for filtration comprising (a) a harness; and (b) a mask body having a grip feature located therein, the grip feature having marking areas to provide an indication of where to hold the mask body for fit. The inventors found that the use of marking areas in

A grip feature is beneficial for both achieving and maintaining a fair fit to the user's face. The grip feature provides a solid surface through which the wearer's fingers can easily grasp the body of the mask to properly position it during dressing and subsequent adjustments and removal. Marking areas provide an indication to the user of where the grip characteristic is located and how to hold it during adjustment operations, and accordingly facilitates user training.

Images, rather than text, have become a progressively popular medium for conveying information to users regarding the operation of various products. Many images have gained universal recognition. The intent of marking areas in the present invention is to create an association in the wearer's mind of the correct place on the respirator to hold the mask body by repositioning and removing it. Marking areas can be, for example, a fingerprint pattern. A fingerprint pattern can be integrated into an area of ultrasonically bonded material to be seen as a contrast, or image, between welded and non-welded areas and can also be felt at the user's fingertips by varying the thickness of the mask on those areas. An image, however, could also be printed on the grip feature to allow for greater visual contrast to the rest of the mask. When marking areas are generally in a circular shape, the effect could be achieved by cutting a crescent shape, or even a small hole, in the grip feature, whose hole or opening would have the additional function of allowing the mask to be hung. On a nail or hook for easy storage away from contaminated surfaces, or even as a method for dispensing. Glossary

The terms presented below will have the meanings as set forth in

defined:

"bisect (s)" means to divide into two generally equal parts; "to understand" or "to understand" means its definition as the standard in patent terminology, being a broad term that is generally synonymous with "including", "having", or "containing". Although "comprises", "includes", "having", and "containing" and variations thereof are broad commonly used terms, this invention may also be suitably described as using more narrow terms such as "essentially consists of" which is a not so broad term as it excludes only those things or elements that would have a deleterious effect on the inventive respirator's performance by serving his intended function;

"clean air" means a volume of atmospheric ambient air that has been filtered to remove contaminants; "contaminants" means particles (including dust, mists, and fumes) and / or other substances which in general may not be considered particles (for example, organic vapors, et cetera) but which may

be suspended in the air;

"transverse dimension" is the laterally extending dimension

through the respirator side by side when the respirator is viewed from the front;

"cup-shaped configuration" means any vase-like shape that is capable of adequately covering a person's nose and mouth;

"outer gas space" means the ambient atmospheric gas into which exhaled gas enters after passing through and beyond the body of the

mask and / or exhalation valve;

"filtration facepiece" means that the mask body itself is designed to filter the air passing through it; there are no separately identifiable injection molded filter cartridges or filter elements attached to or molded into the mask body to achieve this purpose;

"filter" or "filtration layer" means one or more layers of air permeable material, the layer (s) of which is adaptable for the primary purpose of removing contaminants (such as particles) from an airflow that

passes through it;

"filter medium" means an air permeable structure which is

designed to remove contaminants from air passing through it;

"filtration structure" means a construct that includes a filter medium or a filtration layer and optionally other layers;

"first side" means an area of the mask body that is located on one side of a plane that bisects the normal mask body to the transverse dimension; "fit" means any or combination of dressing, removing, or

adjust the position of the mask body;

"flange" means a projecting part which has an area of

sufficient surface to be held by one person;

"frontally" means to extend from the perimeter of the body

mask when the mask body is in a folded condition;

"headgear" means a structure or combination of parts that assists the mask body holder on a user's face;

"marking areas" means mark (s), pattern (s), image (s), aperture (s), identifying texture (s), or a combination thereof;

"integral" means to be manufactured together at the same time, that is, to be made together as one part and not two separately manufactured parts.

which are subsequently joined together;

"interior gas space" means the space between a body of the

mask and face of a user;

"laterally" means extending from a plane bisecting the body of the normal mask to the transverse dimension when

mask body is in a folded condition;

"demarcation line" means a fold, a seam, a

welding line, a bonding line, a dot line, a

hinge, and / or any combination thereof;

"mask body" means an air-permeable structure that is designed to fit over a person's nose and mouth and helps to define an interior gas space separate from an exterior gas space (including the seams and connections that join the layers and the parts of the

same);

"nasal clip" means a mechanical device (other than a nasal foam), the device of which is adapted for use on a body of the

20

25 mask to improve sealing at least around the user's nose; "perimeter" means the outer edge of the body of the mask, the outer edge of which is generally arranged close to a wearer's face when the respirator is being worn by a person;

"fold" means a portion that is designed to be folded

back on itself;

"polymeric" and "plastic" each mean a material which primarily includes one or more polymers and which may contain other

ingredients too;

"plurality" means two or more;

"respirator" means an air filtration device that is used by a person to provide the user with clean air to breathe;

"second side" means an area of the mask body that is located on one side of a plane that bisects the normal mask body to the transverse dimension (where the second side is opposite to the first side);

"tight fit" or "tight fit" means that an essentially hermetic (or substantially leak-free) fit is provided (between the mask body and the wearer's face);

"flap" means a part that has sufficient surface area

to fix another component; and

"extending transversely" means generally extending into the

transverse dimension.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front perspective view of a filtration facepiece respirator 10 according to the present invention being used in the

face of a person;

Figure 2 is a top view of respirator 10 shown in Figure 1;

Figure 3 is an enlarged top view;

Figure 4 is a cross-sectional view of the mask body 12 taken along lines 4-4 of Figure 2; and

Figure 5 is a cross-sectional view of the filtration structure 16 taken along lines 5-5 of Figure 4.

Detailed Description of the Invention

In the practice of this invention, a filtering facepiece respirator is provided that has a grip feature disposed on the mask body. Marking areas are placed on the gripping feature so that the user can readily learn that the attribute is designed to be held by the user during adjustment. The gripping feature may comprise first and second flanges extending both laterally and frontally from the body of the mastic when in an open configuration. The first and second flanges provide "handles" on each side of the mask body to allow the wearer to properly position the mask body during use. The user does not need to pinch the body of the mask to move the mask to an adjustment position on the desired face. Flanges, therefore, provide a very useful means for performing mask adjustment. Marking areas act to inform the user that the flanges are where the mask body should be held during dressing, taking off and adjusting.

Figure 1 shows an example of a flat bend filtration facepiece respirator 10 that can be used in accordance with the present invention to provide clean air to the user for breathing. As illustrated, the filter facepiece respirator 10 includes a mask body 12 and a harness 14. The mask body 12 has a filtration structure 16 through which inhaled air passes before entering the user's respiratory system. . The filtration frame 16 removes contaminants from the environment so that the user breathes clean air. The mask body 12 includes an upper portion 18 and a lower portion 20. The upper portion 18 and the lower portion 20 are separated by a demarcation line 22. In this particular embodiment, the demarcation line 22 is an extending pleat. transversely through the central portion of the mask body. The mask body 12 also includes a perimeter including an upper segment 24a and a lower segment 24b. The harness 14 has a tape 26 that is clipped to a tab 28a. As illustrated, tab 28a is an integral part of

doflange30a.

Figure 2 shows that respirator 10 may have the first and

second flanges 30a and 30b located on opposite sides of the mask body 12. The tape 26 is secured to each flap 28a, 28b using, for example, a clip. Flanges 30a and 30b both project laterally and frontally from the mask body and thus provide a grip feature to the wearer. Each flange projects laterally from the mask body extending away from a plane P that bisects the mask body in x directions. The flanges 30a and 30b tan? They also extend frontally from the mask body 12 as they extend away from the perimeter 24a toward the front edge 22 of the mask body 12 in the direction pointed by the arrow y. Each flange typically occupies a surface area of about 1 to 15 square centimeters (cm 2), more typically about 2 to 12 cm 2, even more typically about 5 to 10 cm 2. Each flange also typically extends away from the mask body at least 2 millimeters (mm), more typically at least 5 mm, and even more typically at least 1 to 2 centimeters (cm). Flanges 30a, 30b may be integrally or non-integrally disposed in the mask body and may comprise one or more or all of the various layers that comprise the mask body. That is, the flanges may be an extension of the material used to make the mask body, or they may be made of a separate material such as a rigid or semi-rigid plastic. The flanges 30a, 30b each have marking areas 32a, 32b located on one or more sides of the flanges. As shown, the marking areas 32, 32 may be in the form of a fingerprint to inform the wearer of where the mask body can be held between the wearer's opposite fingers, for example the thumb and index finger. Marking areas could take other shapes and shapes, for example, concentric circles, ovals, or rectangles. Alternatively, the marking areas could include a hole in the flange so that the user can feel contact between their opposing fingers.

Figure 3 shows an example of a hole 33 that may be provided in marking areas 32b. Marking areas can be created from a weld pattern, a printed image, one or more openings, slit cut (s), perforations, stickiness, or a combination of such things. Marking areas will typically occupy a surface area of about 1 to 6 square centimeters (cm 2), more typically about 2 to 4 cm 2. Although another item such as paint is added to the mask body surface to create the marking areas, the marking areas are typically formed entirely and exclusively of the mask body materials themselves, for example as a weld pattern. Marking areas can be a weld pattern that is noticeable on opposite main flange surfaces - that is, the weld extends across the thickness of the flange. The layers comprising the mask body accordingly can be welded so that the weld pattern is noticeable from the upper or lower surface of the grip feature. An integral flange may have additional welds or fittings 34 provided therein to increase flange stiffness. Alternatively, an adhesive layer may be used between the layers to increase flange stiffness. Using the Flexural Stiffness Test presented below, flanges can have a flexural modulus of at least 10 Mega Pascals (MPa) 1 more typically at least 20 MPa when bent over a major flange surface. At the upper end, the flexural modulus is typically less than 100 MPa, more typically less than 60 MPa. These numbers (ie at both the upper and lower ends) are approximately twice as large when the test is performed along the edges of the sample. Flange stiffness can be measured using a modified ASTM D790 method "Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials," Method I "Three Point Bending Test". Flexural modulus can be calculated according to ASTM D790 in the linear region of stress and strain plot. Although the tabs 28a and 28b are illustrated in Figure 2 as having a shared edge that is part of the perimeter segment 24a, the tabs, however, may extend beyond the circumferential contact portion of the mask body perimeter face. when the mask is located over a user's face, as shown in Figure 1. The face contact periphery generally resides in the outlined area 35 and is therefore not part of the flap perimeter. The perimeter of the mask body may have a series of connections or welds 34 'to join the various layers of the mask body 12. Connection lines 36 may also be provided where the flanges 30a, 30b meet the filtering structure 16. The portion The uppermost 18 may include at least one crease line 38 extending from the first side of the mask body to the second side of the mask body. Examples of grip characteristics other than integral flaps may include the addition of other components attached to the body of the mask such as protrusions, handles, and trim, and may include: plastic injection molded parts; die cut parts made of plastic, metal, and / or cellulosic materials; mechanical coupling devices; adhesive fixed devices made of plastic, metal, and / or cellulosic materials; and mechanically attached devices such as rivets that are deformed during the fixing process. U.S. Patent Application 12 / 338,084 entitled Flat-breather respirator having flanges disposed on the mask body, provides an example of a gripping facepiece respirator suitable for use in

present invention.

Figure 4 illustrates an example of a pleated configuration of

a mask body 12 which may be used in connection with the present invention. As shown, the mask body 12 includes pleats 22 and 38, already mentioned with reference to Figures 1 and 2. The panel or upper portion 18 of the mask body 12 also includes a pleat 40. The panel or lower portion 20 of the mask body mask 12 includes pleats 42, 44, 46, 48, 50, and 52. The lower portion 20 of the mask body 12 may include more filter surface area means than the upper portion 18. The mask body 12 also includes a perimeter blanket 54 which is attached to the mask body along its perimeter. A nasal clip 56 may be centrally disposed in the upper portion 18 of the mask body, adjacent to the perimeter between the filtration structure 16 and the perimeter blanket 54. The nasal clip 56 may be made of a malleable metal or plastic that is capable of being manually adjusted by the user to fit the contour of the user's nose. The perimeter blanket 54 may be folded over the mask body at perimeter 24a, 24b. The perimeter mat 54 may also be an extension of an inner cover mat 58 folded and secured around the edge 24a and 24b. Alternatively, the perimeter blanket could be an extension of the outer cover blanket 60. As shown, the upper portion 18 appears as a pleat panel when the mask body 12 is in a position 10.

15

20

25

bent condition; similarly, the lower portion 20 (Figure 1) appears as a pleated panel when the mask is in its folded storage condition. More or less pleats than shown can be used when providing a flat bend filtration facepiece respirator,

according to the present invention.

Figure 5 illustrates that filtration structure 16 may include a

or more layers such as an inner cover mat 58, an outer cover mat 60, and a filtration layer 62. Inner and outer cover mat 58 and 60 may be provided to protect the filtration layer 62 and to prevent fibers of the filtering layer 62 loosen and enter the interior of the mask. During respirator use, air passes sequentially through layers 60, 62, and 58 before. enter inside the mask. Air that is disposed in the mask's interior gas space can then be inhaled by the wearer. When a user exhales, air passes in the opposite direction sequentially through layers 58, 62, and 60. Alternatively, an exhalation valve (not shown) may be provided in the mask body to allow exhaled air to be rapidly purified from an inner gas space to enter the outer gas space, minimizing air flow through the filtration structure 16. Typically, the blankets 58 and 60 are made from a selection of nonwoven materials that provide a comfortable feel, particularly on the side of the filtration structure that makes contact with the user's face. The construction of various filter layers and cover sheets which may be used in conjunction with the support structure of the present invention is described in more detail below. To improve fit and wearer comfort, an elastomeric seal may be provided to the perimeter of the filtration structure 16. Such a face seal may extend radially inward from the perimeter to contact the wearer's face when the respirator is in place. being dressed up. Examples of face seals are described in U.S. Patents 6,568,392 to Bostock et al., 5,617,849 to Springett et al., And 4,600,002 to Maryyanek et al., And Canadian Patent 1,296,487 to Yard. The filtration structure may also have a mesh or structural mesh juxtaposed against at least one or more layers 58, 60, or 62, typically against the outer surface of the outer covering 60. The use of such a mesh is described in Patent Application. US Serial No. 12 / 338,091, filed December 18, 2008, entitled Expandable Face Mask with Reinforcing Netting.

The filtration structure that is used in connection with the present invention may have a variety of different shapes and configurations. In general, the shape and configuration of the filtration structure corresponds to the overall shape of the mask body. Although a filtration structure has been illustrated with multiple layers including a filtration layer and two blankets, the filtration structure may simply comprise a filtration layer or a combination of filtration layers. For example, a prefilter may be arranged upstream for a more selective and refined downstream filtration layer. In addition, absorbent materials such as activated carbon may be disposed between the fibers and / or several layers comprising the filtration structure. In addition, separate particulate filtration layers may be used in conjunction with absorbent layers to provide filtration for both particulates and vapors. The filtration structure may include one or more stiffening layers which assist in providing a cup-shaped configuration. The filtration structure could also have one or more horizontal and / or vertical demarcation lines that contribute to its structural integrity.

The filtration structure that is used in a mask body of the invention may be of a vapor and gas filter or particle capture type. The filtration structure may also be a barrier layer which prevents the transfer of liquid from one side of the filter layer to the other to prevent, for example, liquid aerosols or liquid splash (e.g., blood) from penetrating the filter layer. . Multiple layers of similar or dissimilar filter media may be used to construct the filtration structure of the invention as required. Filters that may be beneficially employed in a layered mask body of the invention are generally low in pressure drop (e.g., less than about 195 to 295 Pascals at a surface velocity of 13.8 centimeters). pro second) to minimize the mask user's breathing work. The filtration layers may additionally be flexible and may have sufficient shear strength such that they generally retain their structure under the expected conditions of use. Examples of particle capture filters include one or more webs of fine inorganic fibers (such as glass fiber) or polymeric synthetic fibers. Synthetic fiber blankets may include electret-loaded polymer microfibres that are produced from processes such as melt blown. Polyolefin microfibers formed from electrically charged polypropylene are particularly useful for particulate capture applications. An alternative filter layer may comprise an absorbent component for removing harmful or odorous gases from the breathing air. Absorbents may include powders or granules that are bonded to a filter layer may be adhesives, binders, or fibrous structures — see U.S. Patent 6,334,671 to Springett et al. and 3,971,373 to Braun. An absorbent layer may be formed by coating a substrate, such as a fibrous or crosslinked foam, to form a thin coherent layer. Absorbent materials may include activated carbons that are chemically treated or untreated, porous alumina-silica catalyst substrates, and alumina particles. An example of an absorbent filtration structure that can be shaped into various configurations is described in U.S. Patent 6,391,429 to Senkus et al.

The filtration layer is typically chosen to achieve a desired filtration effect. The filtration layer will generally remove a high percentage of particles and / or other contaminants from the gaseous flow passing through it. For fibrous filter layers, the fibers selected depend on the type of substance to be filtered and typically are chosen so that they do not bind during the molding operation. As indicated, the filtration layer may be in a variety of shapes and forms; it typically has a thickness of about 0.2 mm (mm) to mm, more typically about 0.3 mm to 5 mm, and could be a general planar blanket or could be wrinkled to provide an expanded surface area— see, for example, US Patents 5,804,295 and 5,656,368 to Braun et al. The filtering layer may also include multiple filtering layers joined by an adhesive or any other means. Essentially, any suitable material that is known (or later developed) to form a filtration layer can be used as the filtration material. Meltblown fiber blankets, such as those taught in Wente, Van A., Superfine Thermoplastic Fibers, 48 lndus. Eng. Chem., 1342 et seq. (1956), especially when in a persistently electrically charged form (electret), are especially useful (see, for example, U.S. Patent No. 4,215,682 to Kubik et al.). These blown melt fibers may be microfibers which have an effective fiber diameter of less than about 20 micrometers (μητι) (referred to as BMF for "blown microfiber"), typically about 1 to 12 μηι. The effective fiber diameter can be determined according to Davies, CN, The Separation Of Airborne Dust Particles, Institution Of Mechanical Engineers, London, Annals 1B, 1952. BMF blankets containing fibers formed of polypropylene, poly (4-4C) are particularly preferred. methyl-1-pentene), and combinations thereof. Electrically charged fibrillated film fibers taught in van Turnhout, Patent Re. No. 31,285 may also be suitable as well as fibrous rosin wool blankets and fiberglass or solution-blown blankets or electrostatically sprayed fibers, especially in the form of microfilm. Electric charge can be transmitted to the fibers by contacting the fibers with water, as disclosed in US Patent Nos. 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. electrical charge can also be transmitted to the fibers by corona charging, as disclosed in U.S. Patent 4,588,537 to Klasse et al. or by tribe-loading as disclosed in U.S. Patent 4,798,850 to Brown. In addition, additives may be included in the fibers to improve the filtration performance of blankets produced by the hydro-loading process (see U.S. Patent 5,908,598 to Rousseau et al.). Fluorine atoms, in particular, may be arranged as fiber surfaces in the filter layer to improve filtration performance in an oily mist environment - see US Patent 6,398,847 B1, 6,397,458 B1, and 6,409,806 B1 for Jones et al. Typical base weights for BMF electret filtration layers are about 10 to 100 grams per square meter. When electrically charged according to the techniques described herein, for example, a. '507 Angadjivand et al., and when fluorine atoms are included, as mentioned in Jones et al., the basis weight may be about 20 to 40 g / m2 and about 10 to 30 g / m2 respectively.

An inner blanket can be used to provide 10

a soft surface to contact the wearer's face, and an outer covering blanket can be used to capture loose fibers on the mask body or for aesthetic reasons. The cover mat typically does not provide any substantial filtration benefit to the filtration structure, although it may act as a prefilter when disposed outside (or upstream) of the filtration layer. For an adequate degree of comfort, an inner covering blanket typically has a comparatively low base weight and is formed from comparatively thin fibers. More particularly, the cover mat may be formed to have a basis weight of about 5 to 50g / m2 (typically 10 to 30g / m2), and the fibers often used have an average fiber diameter of about 5 to 50g / m2. 24 micrometers, typically about 7 to 18 micrometers, and more typically about 8 to 12 micrometers. Suitable cover mat materials may be blown microfiber (BMF), particularly polyolefin BMF materials, for example polypropylene BMF materials (including polypropylene blends as well as polypropylene blends) and continuous spinning fibers. Blankets that are used in the invention preferably have very few fibers projecting from the surface of the blanket after processing and thus have a smooth outer surface. Examples of blankets which may be used in the present invention are set forth, for example, in U.S. Patent 6,041,782 to Angadjivand, U.S. Patent 6,123,077 to Bostock et al., And WO 96 / 28216A

to Bostock et al.

The tape (s) that are used in the headgear can be made from a

variety of materials such as thermoset rubbers, elastomers

thermoplastics, braided or braided rubber / braid combinations,

inelastic braided components, and the like. The tape (s) can be made of

an elastic material such as a braided elastic material. The tape can,

20

25

preferably be expanded to greater than twice its total length and returned to its relaxed state. The tape could also possibly be increased to three or four times its relaxed state length and can be returned to its original condition without any damage to it when the tensile forces are removed. The elastic limit, therefore, is preferably no less than two, three or four times the length of the tape when in its relaxed state. Typically, the tape (s) is about 20 to 30 cm long, about 3 to 10 mm wide, and about 0.9 to 1.5 mm thick. The tape (s) may extend from the first flap to the second flap as a continuous tape or the tape may have a plurality of parts, which may be joined by additional closures or buckles. For example, the tape may have first and second portions that are joined by a fastener that can be quickly detached by the user when removing the mask body from the face. An example of a tape that may be used in conjunction with the present invention is shown in U.S. Patent 6,332,465 to Xue et al. Examples of locking or locking mechanisms that can be used to join one or more parts of the tape are shown, for example, in the following U.S. Patent Nos. 6,062,221 to Brostrom et al.

5,237,986 to Seppala; and EP1,495,785A1 to Chien. An exhalation valve can also be attached to the body of the

mask to facilitate the purification of exhaled air from the interior gas space. Use of an exhalation valve can improve wearer comfort by quickly removing exhaled warm moist air from inside the mask. See, for example, U.S. Patent Nos. 7,188,622, 7,028,689, and 7,013,895 to Martin et al .; 7,428,903, 7,311,104, 7,117,868, 6,854,463, 6,843,248, and 5,325,892 to Japuntich et al .; 6,883,518 to Mittelstadt et al .; and RE37,974 to Bowers. Essentially, any exhalation valve that provides a suitable pressure drop and that can be properly secured to the mask body can be used in connection with the present invention to rapidly deliver exhaled air from the interior gas space to the exterior gas space.

A nose clip that is used in conjunction with the present invention may be essentially any additional part that assists in improving the fit over the user's nose. Because there are substantial changes in contour to the wearer's face in this region, a nose clip can better assist the mask body in achieving proper fit at this location. The nose clip may comprise, for example, an immovable soft malleable metal-aluminum band which may be shaped to hold the mask in a desired fit relationship over the wearer's nose and where the nose meets the face. An example of a suitable nasal clip is shown in U.S. Patent 5,558,089 and Des. 412,573 to Castiglione. Other nasal clips are described in U.S. Patent Application 12 / 238,737 (filed September 26, 2008); U.S. Publications 2007-0044803A1 (filed August 25, 2005); and 2007-0068529A1 (filed September 27, 2005).

Although the present invention has been described with reference to a particular flat fold mask, the invention may be used in conjunction with flat fold masks which have other configurations - such as those shown in U.S. Patent Nos. 7,069,930 to Bostock et al. and 6,394,090 to Chen, or may be used in conjunction with molded masks — see, for example, U.S. Patent Nos. 7,131,442 to Kronzeret al., 6,923,182 to Angadjivand et al, and 6,827,764 to Springett et al. The invention may also be used in connection with the molded masks mentioned above.

Example

A respirator filtration structure was formed from three layers of nonwoven material and other respirator components. The mask was assembled in two main operations - preform making and mask finishing. The preform making stage included the lamination steps and the attachment of nonwoven fibrous webs, the formation of crease lines, and the attachment of the nasal clip. The mask finishing operation included folding the folds along protruding creased lines, merging the side edges of the mask with the claimed marking areas attribute, cutting the flap into its final shape, and securing the headband.

The respirator's body was formed from three layers of non-woven material: outer covering blanket (205 mm χ 300 mm); a filter material (205 mm χ 300 mm); and an inner blanket (238 mm χ 300 mm). The inner and outer cover sheets were 34 grams per square meter (gsm) continuous spinning nonwoven. The filter material used on the body of the mask was an electret-loaded blown microfiber polypropylene blanket that had a base weight of 59 gsm, a solidity of 6%, and an effective fiber diameter of 7.5 micrometers.

The respirator body was made by pleating each of the layers, which were then ultrasonically welded together using a dot bonding pattern. Ultrasonic splitting was performed using a Model 2000 ultrasonic welding unit from Branson, Danbury, Connecticut1 operated at a ram pressure of 483 kilo pascals (kPa) with a horn amplitude, frequency, and residence time of 100. %, kilohertz (kHz) and 0.6 seconds, respectively. Operating against an anvil with flat top piles, having individual 1.6 mm square face areas arranged in a mesh pattern spaced approximately one centimeter in the center of the piles, the welder's flat-faced horn acted against the anvil in a contact pressure of approximately 6 MPa. With the nonwoven layers attached, the crease lines defining the location of the crease were emphasized on the attached nonwoven layers. The highlighting of the creasing lines was done using a die cutting machine, the USM Corporation Hytronic Model B Cutting Machine, Haverhill, Massachusetts, at 15 shades of force and with a crease ruler matrix. The matrix had nine bars with radius edges that traversed the length of the preform and, when pressed into the preform, created lines in the nonwoven layers. The highlighted lines compressed the blankets together at the point of contact, but did not significantly penetrate or fuse the material.

As a final step in the preform making operation, the extending edges of the inner covering blanket were wrapped around the edges of the preform and ultrasonically welded in place. Ultrasonic welding was performed using a Model 2000X ultrasonic welding unit from Branson, Danbury, Connecticut, operated at a ram pressure of 448 kPa with a horn amplitude, frequency and dwell time of 100%, 20 kHz, and 0.5 seconds, respectively. Operation against an anvil with a contact surface of 4.1 square centimeters, using specified RAM pressure and horn conditions, resulted in contact pressures of 8.5 MPa to bond the preform materials. The anvil area used to connect the perimeter edge of the preform was configured in square flat top piles having individual 1.6 mm square face areas that were arranged in a 34 'pattern as shown in Figure 2. The welder's flat-faced horn acted against an anvil, securing the perimeter blanket to the preform. Using this process, a nasal clip was attached to the top of the preform and was encapsulated between the outer covering blanket and folded over the edge of the inner covering blanket. The nasal clip was a malleable plastic deformable aluminum strip that had the shape shown in Figure 2 and was 9 cm long by 0.5 cm wide by 1 mm thick. In the mask finishing operation, the folds were folded along the crease lines as shown in Figure 4. The folds located above the center fold of the mask were folded so that the outer fold was facing down with the mask open ; This was done to help prevent the buildup of raw matter in the folds of the mask when worn. With the preform appropriately pleated and folded around the center fold, the preform was ultrasonically welded to fuse the side edges of the mask (28a and 28b in Figure 2) and to create the bonded layers of the stiffened flange including the areas. marking handle (32a and 32b in Figure 2). Ultrasonic welding was performed using a Model 2000x welding unit also from Branson, operated at a ram pressure of 483 kPa with a horn amplitude, frequency and dwell time of 100%, 20kHz, and 8 seconds, respectively. The contact area of the anvil for flange material bonding was configured with square flat top piles having individual 1.04 mm face areas that were spaced 2.88 mm from their flat sides, and included the shape of the claimed marking areas. The resulting binding pattern is indicated as 30a in Figure 2. The anvil bars forming the side edge joints of the mask were 95.25 mm long and 9.525 mm wide, with the resulting binding pattern indicated as 36 in Figure 2. The welder's flat-faced horn acted against the anvil resulting in the formation of the weld pattern of the marking areas shown in Figures 2 and 3) and created the bonded flange layers. Anvil angled bar elements sealed the side edges of the mask and pin weld surfaces fused and stiffened the flange material. As a final step in the mask finishing operation, the stiffened flanges were cut to a desired shape, and a headband was clipped to the tabs. The flanges were 1.0 cm wide by 5.0 cm long with a 0.5 cm radius head located at the attachment point of the headband flap. The headband was fixed to the headstock in the flange radius using a Stanley Bostitch, East Greenwich, Rhode Island, Model P6C-8 hand stapler and N0 STH5019 1/4 inch galvanized staples. Flange sections were cut from the mask and tested according to a method defined in Flexural Stiffness Test. The flange sections were tested in two orientations: along the flat plane of the sample and along the edge of the sample as it would be oriented along the flange length. When bent along the flat plane of the sample, the flexural modulus was 27 MPa. When tested along the edge of the sample, it was 66 MPa. The headband was 7.9 mm wide by 0.8 mm thick, Sample No. 125-1 from Providence Braid Co., Pawtucket, Rhode Island. The flanges were able to rotate on a geometric axis parallel to the mask body attachment line and provided a stiffer mask body when opened and worn. Marking areas arranged on the flanges were readily visible as an indication of -

where to hold the mask body.

This invention may undergo various modifications and alterations without departing from its essence and scope. Accordingly, this invention is not limited to that described above, but should be controlled by the limitations set forth in the following claims and any equivalents thereof.

This invention may also be suitably practiced in the absence of any element not specifically disclosed herein.

All patents and patent applications cited above, including those in the Background section, are incorporated in their entirety herein by reference. To the extent of a conflict or discrepancy between the description in such embedded document and the above descriptive report, the above descriptive report shall prevail.

Claims (10)

1. FILTERING FACIAL PART RESPIRATOR, characterized in that it comprises: (a) a harness; (b) a mask body having a gripping feature located therein, the gripping feature having marking areas to provide an indication of where the mask body is to be attached for adjustment. FILTERING FACIAL PART RESPIRATOR according to claim 1, characterized in that the gripping characteristic comprises a flange. FILTERING FACIAL PART RESPIRATOR according to claim 2, characterized in that "the gripping feature comprises a first and a second flange located on opposite sides of the mask body. FILTERING FACIAL PART RESPIRATOR according to Claim 3, characterized in that the marking areas comprise at least a cutout portion in the first and second flanges, respectively. FILTERING FACIAL PART RESPIRATOR according to claim 3, characterized in that the marking areas comprise a first and a second weld line on the first and second flanges, respectively. FILTERING FACIAL PART RESPIRATOR according to claim 4, characterized in that the weld lines look like a fingerprint. FILTERING FACIAL PART RESPIRATOR according to Claim 1, characterized in that the mask body comprises the first and second flanges which are integral with the mask body, the first and second flanges having the first one. and the second notable marking areas on opposite main surfaces of the flange house, and the marking areas resembling a fingerprint. A method of producing a filtering facepiece respirator, comprising: (a) providing a mask body having a gripping characteristic located therein; (b) position marking areas on the grip feature to provide an indication to a respirator user of the location of the mask body for fitting purposes; and (c) attach a headgear to the body of the mask. Method according to claim 8, characterized in that the gripping characteristic comprises the first and second flanges located on opposite sides of the mask body. Method according to Claim 8, characterized in that the first and second marking areas are positioned on the first and second flanges, respectively.