Disposable face mask

A mask for filtering airborne particles having a plurality of plastic layers comprising:

• an upper portion adapted for placement generally over a user's nasal area;
• a lower portion adapted for placement generally over a user's oral area;
• a plurality of ribs extending across a line extending generally from where a user's nose would be ultrasonically formed by ultrasonic welding, and
• wherein said ribs are formed with respect to the adjacent cross-section of the plurality of plastic layers less than the thickness of the cross-section of the plurality of plastic layers.

A mask for filtering airborne particles comprising:

• an upper portion for passing over a user's general nasal area;
• a lower portion for passing over a user's general oral area;
• an ultrasonic weld bonding said upper and lower portions together;
• a pair of scoring lines distal from each other and proximate the ends of said mask that have been impressed into at least said upper portion or lower portion;
• ears folded at least partially along said scoring lines over and onto the mask body and secured thereto;
• and,
• strap means for passing through said ears for securing the mask to a user's head.

A process for making a mask comprising:

• providing a plurality of layers of plastic fabric materials in overlying relationship to each other;
• slitting and sealing said plurality of plastic materials to form two sandwiched portions thereof;
• feeding said two sandwiched portions of material in overlying relationship to each other;
• welding the two sandwiched portions together to form an upper and lower portion of the mask by means of an ultrasonic welding horn overlying a cylinder having cutting scoring lines and welding lines thereon;
• and,
• providing a layer of plastic material between said welding horn and said sandwiched portions, which is not welded to said upper and lower portions.