Disposable face mask and method of manufacture

Abstract

A disposable, foldable face mask with face seal characteristics consistent with the use of high efficiency filtering media. The mask is made of a single multi-layer, generally rectangular sheet of filter material having a generally straight top edge, a pair of generally straight side edges shorter than the top edge and defining respective top corners with the top edge, and a bottom edge. Midway between the side edges a fold line extends perpendicularly from the top edge to a termination point. The bottom edge has a configuration which is symmetrical on either side of the fold line, and includes a pair of side portions which define respective bottom corners with the side edges. The side portions of the bottom edge extend from the bottom corners to respective transition points. Between the transition points and the fold line termination point there is a generally triangular cutout, such that further portions of the bottom edge extend to the fold line termination point. The sheet is laterally folded on the fold line. On either side of the fold line, the bottom edge side portions and the bottom edge further portions are joined such that a mask body is formed. The mask body is essentially flat for storage and, when unfolded, has an opening defined by the sheet top and side edges and sized to cover the nose and mouth of a wearer. A mask tieing device, such as a pair of conventional ties, is attached to the corners.