Patent ID: 8580182
Filing Date: 2013-11-12
Classification: A41D,A62B,D04H,Y10T

Abstract:
1. A process for making a molded respirator comprising: a) forming a monocomponent monolayer nonwoven web containing a bimodal mass fraction/fiber size mixture of intermingled continuous monocomponent polymeric microfibers and larger size fibers of the same polymeric composition and wherein a histogram of mass fraction vs. fiber size in μm exhibits a larger size fiber mode of about 10 to about 50 μm, b) charging the web, and c) molding the charged web to form a cup-shaped porous monocomponent monolayer matrix, the matrix fibers being bonded to one another at at least some points of fiber intersection and the matrix having a King Stiffness greater than 1 N.