Methods of forming fibrous filtration face masks

A method of forming a fibrous face mask, which comprises:

• (a) passing in superimposed relationship at least one layer of filtering material and at least one layer of non-woven fibrous material containing at least about 40 wt. % thermally bonding fibers based on the weight of the non-woven fibrous material, at least about 10 wt. % of the non-woven fibrous material being bicomponent fibers, through a heating stage where the thermally bonding fibers, including at least one component of the bicomponent fibers, are softened;
• and thereafter
• (b) molding the superimposed layers to the shape of a face mask in molding members that are at a temperature below the softening temperature of the thermally bonding fibers, including the at least one softened component of the bicomponent fibers, the molding occurring while the thermally bonding fibers and bicomponent fibers are still able to permit fiber bonding.