Facemasks with material layers for enhanced bonding process

A disposable facemask, comprising:

• a filter body having an opening sized to cover a nose and a mouth of a wearer, the filter body comprising an upper portion and a lower portion,
• each of the upper and the lower portions comprising an outer mask layer, an inner mask layer, and one or more intermediate layers disposed between the outer mask layer and the inner mask layer, the outer mask layer, the inner mask layer, and the one or more intermediate layers of each of the upper and the lower portions being bonded together via thermal or ultrasonic bonding at bond locations along three sides of the facemask to define a duckbill-style facemask, wherein the bond locations comprise additional layers than remaining portions of the filter body, wherein the additional layers comprise folded-over edge binders constructed from a spun-laced polyester, thermally-bonded bicomponent materials, or polypropylene or polyethylene non-porous plastic films,
• wherein the one or more intermediate layers are constructed of a nonwoven web layer comprising thermoplastic filaments formed from a random copolymer or the random copolymer blended with a homopolymer, the random copolymer having a low peak melting point within a temperature range between 137 and 153 degrees Celsius so as to decrease a dwell time of the bond locations containing the additional layers as compared to a dwell time of a facemask constructed of material layers having random copolymers with a peak melting point outside of the temperature range.