Barrier Mask

Abstract

A barrier mask, or face mask is provided that includes a mask body that includes a filter portion, an upper elastic portion, and a lower elastic portion, where the mask body includes at least one meltblown layer. The face mask also includes one or more elastic straps. A method of forming a face mask is also provided, where the method includes electrostatically treating the meltblown layer during the face mask formation process.

What is claimed: 
     
         1 . A barrier face mask comprising:
 a mask body formed from one or more nonwoven web layers comprising
 a seamless filter portion, 
 an upper elastic portion, and 
 a lower elastic portion; 
   at least one elastic strap, wherein each elastic strap is attached to a first side and an opposed second side of the mask body.   
     
     
         2 . The face mask according to  claim 1 , wherein the mask body further comprises at least two layers, and wherein one or more of the layers is formed from a meltblown nonwoven web. 
     
     
         3 . The face mask according to  claim 1 , wherein the meltblown nonwoven web has been electrostatically treated. 
     
     
         4 . The face mask according to  claim 1 , wherein the face mask filters 70% or more of particles having a size of 0.65 microns or greater. 
     
     
         5 . The face mask according to  claim 1 , wherein the mask body includes a spunbond nonwoven layer and a meltblown nonwoven layer. 
     
     
         6 . The face mask according to  claim 1 , wherein the mask body includes a spunbond-meltblown-spunbond layer, and a meltblown nonwoven layer. 
     
     
         7 . The face mask according to  claim 1 , wherein the upper elastic portion, the lower elastic portion, or both the upper elastic portion and the lower elastic portion are disposed between a first and a second nonwoven layer of the mask body. 
     
     
         8 . The face mask according to  claim 1 , wherein the upper elastic portion, the lower elastic portion, or both the upper elastic portion and the lower elastic portion are laminated to the one or more nonwoven web layers. 
     
     
         9 . The face mask according to  claim 1 , wherein the at least one elastic strap is formed from the same elastic as the upper elastic portion, the lower elastic portion, or both the upper elastic portion and the lower elastic portion. 
     
     
         10 . The face mask according to  claim 1 , wherein the face mask comprises at least two straps. 
     
     
         11 . The face mask according to  claim 1 , wherein the mask body has a length in an extended state of about 200 millimeters to about 350 millimeters. 
     
     
         12 . The face mask according to  claim 1 , wherein the at least one elastic strap has a length in an extended state of about 200 millimeters to about 350 millimeters. 
     
     
         13 . The face mask according to  claim 1 , wherein the at least one elastic strap has a width in an extended state of about 25 millimeters to about 75 millimeters. 
     
     
         14 . The face mask according to  claim 1 , wherein the face mask exhibits an air permeability according to ASTM D737 of about 20 cfm or greater. 
     
     
         15 . A method of forming a face mask comprising:
 forming a laminate comprising
 unwinding a first nonwoven web, 
 placing one or more elastic members in an upper region, a lower region, or both an upper region and a lower region, 
 unwinding a second nonwoven web, and 
 laminating the first nonwoven web, one or more elastic members, and the second nonwoven web; 
   attaching one or more straps to the laminate, wherein each strap is attached to a leading edge and an opposed trailing edge of the laminate;   wherein the one or more straps are attached to the laminate during an in-line process.   
     
     
         16 . The method of  claim 15 , wherein the one or more straps are cut off of the laminate prior to attaching the straps to the laminate. 
     
     
         17 . The method of one of  claim 15 , wherein the second nonwoven web is a meltblown nonwoven web, and wherein the method includes unwinding an untreated meltblown web and subjecting the untreated meltblown web to an electrostatic treatment prior to laminating the meltblown web to the first nonwoven web and the one or more elastic members. 
     
     
         18 . The method of  claim 15 , wherein the first nonwoven web is a spunbond nonwoven web or a spunbond-meltblown-spunbond fabric. 
     
     
         19 . The method of  claim 15 , wherein an adhesive is applied to the one or more elastic members. 
     
     
         20 . The method of  claim 15 , where the laminate, the one or more straps, or both the laminate and the one or more straps are held in a stretched state during lamination, attachment of the one or more straps, or both lamination and attachment of the one or more straps.