# US 10,245,537 B2 · Molded respirator having outer cover web joined to mesh > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,245,537 B2 - Document ID: US10245537B2 - Status: Granted - Kind: B2 - Application number: 13/465,827 - Filed: 2012-05-07 - Published: 2013-11-07 - Granted: 2019-04-02 - Earliest claimed: 2012-05-07 - Assignees: 3M Innovative Properties Company - Applicants: Seyed A. Angadjivand; John M. Brandner; Nhat Ha T. Nguyen - Inventors: Seyed A. Angadjivand; John M. Brandner; Nhat Ha T. Nguyen - Web page: https://patentgrep.com/patent/US10245537B2 ## CPC - B01D 39/1623: {of synthetic origin} - A62B 23/025: {the filter having substantially the shape of a mask (surgical face masks A41D13/11)} - B01D 39/083: {of organic material} - B29C 43/203: {Making multilayered articles} - A41D 13/1138: {with a cup configuration} - B01D 2239/0435: Electret - B01D 2239/065: More than one layer present in the filtering material - B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)} - B29C 66/545: {one hollow-preform being placed inside the other} - B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)} - B29C 66/73115: {Melting point} - B29L 2031/14: Filters {(optical filters B29L2011/0066, sieves or screens B29L2031/737)} - B29L 2031/4835: {Masks} - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - A62B: DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING (valves specially adapted for medical use A61M39/00; life-saving devices, apparatus or methods specially adapted for use in water B63C9/00; divers' equipment B63C11/00; specially adopted for use with aircraft, e.g. parachutes, ejector seats, {B64D17/00, B64D25/10}; rescue devices peculiar to mining E21F11/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A41D: OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A respirator 10 that has a mask body 12 and a harness 14 that is attached to the mask body 12. The mask body 12 includes a filtering structure 18 that has an inner cover web 40a, an outer cover web 40b that comprises melt-blown fibers and staple fibers, and a filtration layer 42 that is located between the inner and outer cover webs 40a, 40b. The mask body 12 also has a mesh 20 that is joined to the outer cover web 40b. A respirator having this construction is more resistant to inward collapse of the filter media during breathing and is more aesthetically pleasing. ## Claims ### Claim 1 A method of making a filtering face-piece respirator, which method comprises: (a) providing filtering pre-form that comprises an inner cover web and a filtration layer; (b) providing a combined structure that has a molded plastic mesh joined to an outer cover web; and (c) inserting the filtering pre-form into the molded plastic mesh and welding the pre-form to the combined structure at least at the perimeter. ### Claim 2 (depends on 1) The method of claim 1, further comprising electrically charging microfibers of the outer cover web. ### Claim 3 (depends on 1) The method of claim 1, wherein the molded plastic mesh is laminated to the outer cover web. ### Claim 4 (depends on 1) The method of claim 1, wherein welding the pre-form to the combined structure comprises ultrasonically bonding the pre-form to the combined structure at least at the perimeter. ### Claim 5 (depends on 1) The method of claim 1, wherein the outer cover web is coextensive and in intimate contact with the molded plastic mesh over the whole mask body inward from the perimeter. ### Claim 6 (depends on 1) The method of claim 1, wherein providing the filtering pre-form comprises: disposing the inner cover web on two layers of filter media to form a three-layer laminate; folding the three-layer laminate in half along a fold to form a six-layer stacked laminate structure, wherein the filter media provides outer layers of the stacked laminate structure; bonding the stacked laminate structure together to form a bond and the filtration layer; removing portions of the inner cover web and filter media between the bond and the fold; and unfolding the stacked laminate structure to provide the pre-form. ### Claim 7 (depends on 6) The method of claim 6, wherein the bond comprises a sinusoidal wave form bond. ### Claim 8 (depends on 1) The method of claim 1, wherein the mesh contains cells that each have a hexagonal shape. ### Claim 9 (depends on 1) The method of claim 1, wherein the mesh has a hexagonal or octagonal pattern. ### Claim 10 (depends on 1) The method of claim 1, wherein the mesh has a hexagonal pattern. ### Claim 11 (depends on 10) The method of claim 10, wherein each hexagon occupies an area of 20 to 40 square millimeters. ### Claim 12 (depends on 11) The method of claim 11, wherein the mesh comprises strands that have an average cross-sectional area of 0.2 to 3.2 mm2. ### Claim 13 (depends on 1) The method of claim 1, wherein the molded plastic mesh and melt-blown fibers of the outer cover web contain polypropylene. ### Claim 14 (depends on 1) The method of claim 1, wherein the outer cover web comprises melt-blown fibers and staple fibers, the melt-blown fibers comprising a polymeric material that has a first melting point. ### Claim 15 (depends on 14) The method of claim 14, wherein the plastic mesh contains a polymeric material that has a second melting point similar to the first melting point. ### Claim 16 (depends on 15) The method of claim 15, wherein the first melting point is 130 to 170° C. ### Claim 17 (depends on 16) The method of claim 16, wherein the second melting point is 130 to 170° C. ### Claim 18 (depends on 15) The method of claim 15, wherein the first and second melting points are within 10° C. or less of each other. ### Claim 19 (depends on 1) The method of claim 1, wherein the filtration layer comprises sorptive materials disposed between fibers of the filtration layer. ### Claim 20 (depends on 1) The method of claim 1, wherein the filtering pre-form further comprises a sorptive layer.