Stiffened filter mask

Abstract

A flat-folding mask includes a filter layer forming a rim. The filter layer has first and second side panels extending from the rim. A substantially centrally located front panel bridges the first and second side panels, the front panel being substantially flat. The filter layer further includes a fused portion that is seamless and spaced from the rim. Triangular pleats may add support to the side walls and increase the effective filtration area of the mask.

1 - 49 . (canceled) 
     
     
         50 . A method of manufacturing a mask having a filter layer, the method comprising:
 folding the filter layer to form two sections, each section having two ends and one side;   reshaping the two ends of each section to form two reshape lines, each of the two reshape lines having a non-linear portion; and   connecting the two sections along the two reshape lines such that the two sections form a pocket having a rim, wherein when the pocket is open at least two side panels extend from the rim to a front panel.   
     
     
         51 . The method according to  claim 50 , wherein folding the filter layer includes folding along a center line running longitudinal to the front panel. 
     
     
         52 . The method according to  claim 50 , further comprising forming at least one pleat. 
     
     
         53 . The method according to  claim 52 , wherein forming the at least one pleat includes forming a first pleat and a second pleat, the front panel adjoining the first pleat and the second pleat. 
     
     
         54 . The method according to  claim 52 , wherein the at least one pleat has a distal end, further comprising attaching the distal end of the at least one pleat to a portion of the filter material between the rim and the front panel. 
     
     
         55 . The method according to  claim 52 , wherein forming the at least one pleat includes folding the reshape lines across the non-linear portion. 
     
     
         56 . The method according to  claim 50 , further comprising fusing an unpleated portion of the filter layer, the fused unpleated portion being seamless and stiffer relative to a second portion of the filter layer. 
     
     
         57 . The method according to  claim 56 , wherein fusing occurs prior to the step of folding. 
     
     
         58 . The method according to  claim 56 , wherein fusing occurs subsequent to the step of folding. 
     
     
         59 . The method according to  claim 56 , wherein fusing includes ultrasonic welding. 
     
     
         60 . The method according to  claim 56 , wherein fusing the unpleated portion includes fusing a first and second portion in the front panel, the first and second portions being substantially parallel. 
     
     
         61 . The method according to  claim 60 , wherein the first and second unpleated portions run substantially parallel to each other in a direction longitudinal to the front panel 
     
     
         62 . The method according to  claim 60 , wherein first and second unpleated portions run substantially parallel to each other in a direction latitudinal to the front panel. 
     
     
         63 . The method according to  claim 56 , wherein fusing the unpleated portion includes fusing at least one unpleated portion running substantially from the rim to the front panel. 
     
     
         64 . The method according to  claim 63 , further comprising pulling on the rim to open the pocket. 
     
     
         65 . The method according  50 , wherein the front panel is substantially flat. 
     
     
         66 . The method according to  claim 50 , further comprising reshaping the side of one of the sections to form a first tab and a second tab, the first tab and the second tab extending seamlessly from the rim. 
     
     
         67 . The method according to  claim 66 , further comprising attaching a headstrap to the first tab and the second tab. 
     
     
         68 . The mask according to  claim 66 , wherein further comprising folded the first tab and the second tab substantially near the rim. 
     
     
         69 . The mask according to  claim 50 , wherein the non-linear portion is concave. 
     
     
         70 . The mask according to  claim 50 , wherein the non-linear portion is convex. 
     
     
         71 . The product formed by the process of  claim 50 . 
     
     
         72 . A method of manufacturing a mask having a filter layer, the method comprising:
 forming a fused portion in the filter layer, the fused portion being seamless;   connecting two planar surfaces of the filter layer to form a pocket having a rim, the fused portion spaced from the rim; and   pulling on the rim to open the pocket, the filter layer forming at least three side panels that extend from the rim to define a perimeter of a front panel.   
     
     
         73 . The method according to  claim 72 , wherein the front panel is substantially flat. 
     
     
         74 . The method according to  claim 72 , wherein the at least three side panels include a top side panel, a bottom side panel, a left side panel, and a right side panel. 
     
     
         75 . The method according to  claim 72 , wherein forming the fused portion includes forming a first and second fused portion in the front panel, the first and second fused portions being substantially parallel. 
     
     
         76 . The method according to  claim 75 , wherein the first and second fused portions run substantially parallel to each other in a direction longitudinal to the front panel. 
     
     
         77 . The method according to  claim 75 , wherein first and second fused portions run substantially parallel to each other in a direction latitudinal to the front panel. 
     
     
         78 . The method according to  claim 72 , wherein forming the fused portion includes forming at least one fused portion running substantially from the rim to the front panel. 
     
     
         79 . The method according to  claim 72 , wherein forming the fused portion includes fusing substantially a perimeter of the front panel, wherein the front panel within the perimeter does not include the fused portion. 
     
     
         80 . The method according to  claim 72 , further comprising forming a first pleat and a second pleat, the first pleat connected to the second pleat by the front panel. 
     
     
         81 . The method according to  claim 72 , further comprising reshaping one of the two planar surfaces to form a first tab and a second tab extending seamlessly from the rim. 
     
     
         82 . The method according to  claim 81 , further comprising attaching a headstrap to the first tab and the second tab. 
     
     
         83 . The mask according to  claim 81 , further comprising folding the first tab and the second tab substantially near the rim. 
     
     
         84 . The mask according to  claim 72 , wherein the fused portion is unpleated. 
     
     
         85 . The product formed by the process of  claim 72 . 
     
     
         86 - 110 . (canceled)