MXPA97006644A - Personal protective respirator devices, flattened by folding and processes for preparation - Google Patents

Abstract

The present invention relates to a personal device for respiratory protection, characterized in that it comprises: a) a flat central portion having first and second edges, b) a first flat member attached to the first edge of the central portion, either through a folding, sewing, welding or joining line, said folding, joining, welding or stitching of the first member being substantially coextensive with the first edge of the central portion, and c) a second flat member attached to the second edge of the central portion, either through a folding, sewing, welding or joining line, said folding being, welding or seaming of the second member, substantially coextensive with the second edge of the central portion, at least one of the central portion and the first and Second members are formed from filter media, and the device is capable of being flattened by folding for storage with the first and second members that are in at least partial face-to-face contact with a common surface of the central portion and, during use, are capable of forming a cup-shaped air chamber over the user's nose and mouth, with the edges unattached from the central portion and the first and second members of the unattached edges are adapted to contact and be secured to the nose, cheeks and chin of the user, and the outer limit of unbonded edges that are adapted to make contact with the nose, cheeks and chin of the user, being less than the perimeter of the device in the storage state flattened by collapsing

Description

PERSONAL PROTECTIVE RESPIRATOR DEVICES, FLAMMED BY FOLDING AND PROCESSES FOR YOUR PREPARATION Field of the Invention The present invention relates to respirators or face masks that are capable of being flattened by folding during storage and forming a cup-shaped air chamber over the mouth and nose of a user during use.

BACKGROUND OF THE INVENTION Filtering respirators or face masks are used in a wide variety of applications when it is desired to protect the respiratory system of a human from particles suspended in the air or from harmful or unpleasant gases. In general, such respirators or face masks are one of two types - an arched shape shaped like a cup or a flattened shape by folding. The flattened form by folding has advantages since it can be carried in a user's bag until it is needed, and REF: 25444 re-flattened by folding to keep the interior clean between uses. The flattened shape by folding the face mask has been constructed as a fabric which is rectangular in shape and has pleats or pleats that run generally parallel to the wearer's mouth. Such constructions may have a stiffening element to keep the face mask away from contact with the user's face. Stiffening has also been provided by fusing a crease or pleat across the width of the face mask in a laminated structure or by providing a seam across the width of the face mask. Also disclosed is a pleated respirator which is centrally folded in the horizontal direction to form opposite upper and lower faces. The respirator has at least one horizontal pleat essentially central to the opposite faces to reduce the filter medium in the vertical direction and at least one additional horizontal pleat in each of these opposite faces. The central pleat is shorter in the horizontal dimension with respect to the pleats on the opposite sides, which are shorter in the horizontal dimension relative to the maximum horizontal dimension of the filter medium. The central pleating together with the pleats on the opposite sides forms a self-supporting bag. Also disclosed is a respirator made from a bag of flexible filtration sheet material having a generally tapered shape with an open edge at the larger end of the bag, and a closed end at the smaller end of the bag. The closed end of the bag is formed with fold lines defining a generally quadrilateral surface comprising triangular surfaces which are folded to extend in an inward direction of the bag, the triangular surfaces being facing each other and in use , relatively inclined to each other. More complex configurations that have been described include a cup-shaped filtering face piece, made from a bag of filtration sheet material having opposite side walls, a generally tapered shape with an open end at the larger end and a closed end at the smaller end. The edge of the bag at the closed end is curved outwards, for example, defined by straight lines of intersection and / or curved lines, and the closed end is provided with fold lines defining a surface that is folded in the inward direction of the closed end of the bag, to define a hollow that extends inwards, and in general conical, to make the bag rigid against breaking against the user's face when inhaling. A face mask is also described having an upper part and a lower part with a generally central part between them. The central part of the body portion is folded in a backward direction around a vertical fold or groove or fold line which divides it substantially in half. This folding fold lineWhen the mask is worn, it is more or less aligned with an imaginary vertical line that passes through the center of the forehead, the nose and the center of the mouth. The upper part of the body portion extends upwardly at an angle from the upper edge of the central part, so that its upper edge contacts the bridge of the nose and the area of the cheekbone of the face. The lower portion of the body portion extends in a downward direction and in the direction of the throat forms the lower edge of the central portion, to provide coverage below the chin of the user. The mask is superimposed, but does not make contact directly, with the lips and mouth of the user.

BRIEF DESCRIPTION OF THE INVENTION The present invention provides a personal respiratory protection device comprising: a flat central portion having first and second edges, a first flat member attached to the first edge of the central portion either through a folding line , sewing, welding or joining, said folding, joining, welding or stitching of the first member is substantially coextensive with the first edge of the central portion, and a second flat member attached to the second edge of the central portion either through a line of folding, sewing, welding or joining, said folding or joining, welding or sewing of the second member is substantially coextensive with the second edge of the central portion, at least one of the central portion and the first and second members are formed from filter media, and the device is capable of being flattened by folding to be stored with the first and second members that are in at least partial face-to-face contact with a common surface of the central portion and, during use are capable of forming a cup-shaped air chamber over the nose and mouth of the user, with the disjoint edges of the central portion and the first and second members adapted to contact and be secured to the nose, cheeks and chin of the user and the outer edge of the unattached edges which are adapted to make contact with the nose, cheek and chin of the user, which is less than the perimeter of the device in the state of storage flattened by folding. The additional portions may optionally be coupled to the unbonded edges of the first and second members. The additional portions may optionally be coupled to the central portion. The configuration of the respiratory device flattened by folding can be rectangular to substantially elliptical. The respiratory device, when deployed for use, is substantially cup-shaped. The filter medium comprising at least one of the first member, the central portion and the second member, can be a non-woven fabric such as one formed from microfibers, or it can be multilayered, each layer having similar filtration properties or not similar. The filter means can, of course, also comprise any two or all of the first member, the central portion and the second member, as well as the additional portions. The respirator devices of the present invention may further comprise headbands or other means such as adhesive for holding the respirator device in place on the wearer's face, nasal clamps or any other means to provide good contact of the respirator device with the nose of the respirator. user, exhalation valves, and other common accoutrements for respirators and face masks such as, for example, face seals, eye shields and neck covers. When the breathing device is constructed with a nasal clamp, the nose clamp can be on the outer portion of the first member of the breathing device, and a cushion member such as a piece of foam can be placed directly below the nose clamp on the nose. Internal surface of the first member or nasal clamp can be on the inner surface of the first member and a cushion member can be placed covering the nasal clamp, or when the ventilator comprises multiple layers, the nasal clamp can be placed between the layers. "The respirator devices of the present invention include, for example, respirators, surgical masks, aseptic room masks, face shields, dust masks, respiration heating masks, and a variety of other face coats." Respiratory or respiratory devices of the present invention can be designed to provide improved sealing engagement with the user's face than some other types of cup-shaped respirators or face masks which contact the user's face at the periphery of the respirator at an acute angle, with minimum contact region, which increases discomfort to the user and potentially minimizes coupling to the perimeter of the respirator. A process for producing personal breathing or breathing devices to provide respiratory protection to a user is further provided, comprising: a) forming a flat central portion, said central portion having at least a first edge and a second edge; b) the coupling of a first flat member to the central portion at the first edge of the central portion with a folding, joining, welding or sewing, the folding edge, joining, welding or sewing of the first member is substantially coextensive with the first edge of the central portion; c) the coupling of a second flat member of the central portion on the second edge of the central portion with a folding, joining, welding or sewing, the edge being folded, joined, welded or sewn of the second member, substantially coextensive with the second. edge of the central portion; with the proviso that at least one of the central portion of the first member and the second member comprises filter means and the device that is capable of being flattened by folding for storage and, in use, that is capable of forming a chamber of cup-shaped air over the nose and mouth of the user, and the unbonded edges of the central portion, the first member and the second member adapted to make contact and be secured to the user's nose, cheeks and chin and the outer limit of the unbonded edges which are adapted to make contact with the user's nose, cheeks and chin, is less than the perimeter of the device in the storage state flattened by folding. The additional portions may optionally be coupled to the unbonded edges of the first and second members. A process for producing personal respiratory protection devices is also provided comprising the steps of forming a rectangular sheet of filter media, folding a first long edge towards the center of the sheet, to form a first member folding the second edge long towards the center of the sheet to form a second member, and sealing the edges not folded. The process may optionally include additional portions coupled to the first and second members at their non-folded edges through additional folds or joints. A process for preparing personal respiratory protection devices is also provided, comprising the formation of a first elliptical filter media sheet having two edges, the formation of a second elliptical filter media sheet having two edges, at least one side of each sheet having a common shape, joining the common shaped edges, folding the unbonded edge of the second sheet towards the joined edge, forming a third elliptical sheet of filter medium having two edges, at least one edge of which it has a common shape with the unbonded edge of the first sheet, placing the third sheet on the second sheet and joining the common shaped edges of the first and third sheets. Each process is suitable for the high-speed production method and may comprise additional steps as necessary for the treatment of headbands, nasal clamps and other components typical of respiratory devices.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front view of a personal protective respiratory device of the invention in the configuration flattened by folding.

Figure 2 is a cross-sectional view taken along line 2-2 of the personal protective respiratory device shown in FIG.

Figure 1.

Figure 3 is a front view of the personal protective respiratory device of Figure 1, shown in the open configuration ready for use.

Figure 4 is a side view of the personal protective respiratory device of Figure 1, shown in the open configuration ready for use.

Figure 5 is a cross sectional view of yet another embodiment of a personal protective respiratory device of the present invention in the configuration flattened by folding.

Figure 6 is a perspective view of the personal protective respiratory device of Figure 5, shown partially open.

Figure 7 is a front view of yet another embodiment of a personal protective respiratory device of the present invention, in the configuration flattened by folding.

Figure 8 is a front view of the personal protective respiratory device of Figure 7, shown in the open configuration ready for use.

Figure 9 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figure 10 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figure 11 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figure 12 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figures 13a-13p are front views of various additional alternative embodiments of the present invention.

Figure 14 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figure 15 is a front view of yet another embodiment of a personal protective respiratory device of the present invention.

Figure 16 is a front view of yet another embodiment of a personal respiratory protection device of the present invention.

Figure 17 is a schematic illustration of an exemplary manufacturing process for producing a personal protective respiratory device, flattened by folding.

Figures 18-20 illustrate intermediate network configurations of the exemplary manufacturing process of Figure 14.

Figure 2 illustrates a strip of face masks manufactured according to the process of Figures 17-20.

Detailed description of the invention In one embodiment of the invention as shown in Figure 1, a front view of the personal respiratory protection device 10, the device has a generally rectangular shape when in the folded form, for storage in a package before use or in a user's bag. A side view of the personal respiratory protection device 10, shown in Figure 2, shows the device having a central portion 12, a first member 14 and a second member 16. The central portion and the first and second members are attached eg , as shown in Figure 2 by the folds 15 and 17, or the first and second members can be attached or stitched to the central portion. The configuration is held in place by edge seals 11 and 11 ', which may extend from the fold 15 to the fold 17 as shown, or these may extend partially from the fold 15 to the fold 17. Edge seals 11 and 11 'may be substantially straight, as shown, or may be curved. Figures 1 and 3 also show coupling means 18, 18 'for coupling, for example, of an upper band or head, to hold the device in place on the face of a user. When the device is a multi-layer construction, having for example a layer or layers of filter media, an optional cover layer, and an optional stiffening layer, the perimeter edges of the first and second members 14 and 16 are also joined together. . The personal respiratory protection device 10 is shown in Figures 3 and 4, where the common parts are identified as in Figures 1 and 2, in their open configuration, ready to be used, which have the general shape of a cup or bag. which provides the user with the benefits "away from the face" of a cup shaped breathing device. The "cup-face" design of the respirator device of the invention provides a peripheral region formed by the edges 24 and 26 of the first and second members, respectively, to seal the respiratory device against the wearer's face. Figure 3 shows the personal respiratory protection device 10 with nasal clamp 28, optional. To allow the user to move the jaw further, a generally wide pleat or pleat can be formed on the first member 14 or on the second member 16 of the respiratory device, just above the folding 15, or just below the folding or joining 17. In another embodiment shown in Figures 5 and 6, where common parts are identified as in Figures 1-4, the additional members 20 and 22 are coupled to the first and second members 14 and 16 of the respiratory device 10 ', by the folds 21 and 23, or by joining or sewing (not shown). The additional members 20 and 22 can be sealed with the central portion 12 and first and second members 14 and 16 in the edge seals 11, 11 ', but preferably they are not sealed in the edge seals as shown in Figures 5 and 6, to provide improved sealing at the periphery of the respiratory device 10 ', due to the ability of the additional portions 20 and 22 to pivot at the coupling points 25 and 25'. Figure 6 shows the respiratory device 10 'with the optional nasal clamp 28, located on the additional member 20. In this embodiment, when multiple layers are used to form the respiratory device, the peripheral edges of the additional members 20 and 22 they are also preferably joined. The width of the central portion 12 of the personal respiratory protection device 10, extends between the edge seals 11 and 11 ', or the junctions located in the same position as the edge seals 11 and 11', is preferably approximately 160. at 220 mm in width, more preferably from about 175 to 205 mm, still more preferably from about 185 to 190 mm in width. The height of the central portion 12 of the respiratory device 10 extending between the pleats 15 and 17, is preferably about 30 to 110 mm in height, more preferably about 50 to 100 mm in height, more preferably about 75 to 80 mm in height. mm height The width of the first member 14 and the second member 16 of the respiratory device 10 are preferably approximately the same as those of the central portion 12. The depth of the first member 14 extending from the fold 15 towards the peripheral edge of the first member 14 of the respiratory device 10 or the fold 21 of the respiratory device 10 ', is preferably from about 30 to 110 mm, more preferably from about 50 to 70 mm, more preferably from about 55 to 65 mm. The depth of the second member 16 extending from the fold 17 towards the peripheral edge of the second member 16 of the respiratory device 10 towards the fold 23 of the respiratory device 10 ', is preferably from about 30 to 110 mm, more preferably from about 55 to 75 mm, and even more preferably from about 60 to 70 mm. The depths of the first member 14 and the second member 16 may be the same or different, and the sum of the depths of the first and second members preferably does not exceed the height of the central portion. The additional members 20 and 22 in the respiratory device 10 'are preferably approximately of the same width as the first and second members 14 and 16. The additional member 20 in the respiratory device 10' is preferably from about 1 to 95 mm, more preferably about 5 to 40 mm, more preferably about 5 to 30 mm deep. The additional member 22 of the respiratory device 10 'is preferably from about 1 to 95 mm, more preferably from about 3 to 75 mm, still more preferably from 3 to 35 mm in depth. The seals of the end edges are preferably about 1 to 25 mm, more preferably about 5 to 10 mm from the outer edges of the central portion 12, the first member 14 and the second member 16, and are preferably from 1 to 10 mm in width, more preferably 2 to 5 mm in width. When the additional portions 20 and 22 are present as in the respiratory device 10 ', such portions may be, but preferably are not, included in the edge seals 11, 11'. In such respiratory devices as 10 and 10 ', the outer limit of the unattached edges which contact the nose, cheeks and chin of the user in the open configuration shown in Figures 3, 4 and 6, is less than the perimeter of the device in the storage state flattened by folding. An additional embodiment which is referred to as elliptical, is shown in Figures 7, 8, 9, 10, 11 and 12. In Figure 7, the respiratory device 50, shown in front view in its folded or storage configuration , includes a central portion 52, and joints 55 and 57. Coupling means 58, 58 'are also shown for engaging, for example, a headband 59 to hold the respiratory device in place on the face of a user. In Figure 8, the respiratory device 50 is shown in front view in its deployed configuration ready for use, with the first member 54 attached to the central portion 52 at the joint 55, and the second member 56 attached to the central portion. 52 at the junction 57. When the respiratory device is formed of multiple layers of material, the perimeter edges of the first member 54 and the second member 56 are also preferably joined. Figure 8 further shows a nasal clamp 70 on the first member 54 and a projection 62 on the central portion 52, with a comparable projection or coupling projection, on the first member 54 (not shown). The nose clamp 60 provides improved fit and the nose 62 with its twin projection on the first member 54 provides improved comfort and fit. In some cases, an improvement in the fit can be obtained by folding the outer edge of the first member 54 inwardly, for example, towards the face of a user. Nasal clamp 60, if present, can be placed within the fold. To allow the user a greater degree of movement of the jaw, a generally wide pleat or crease can be formed in the first member 54 or in the second member 56 of the respiratory device, just below the crease 57. such respiratory devices as 50 and 50 ', the outer limit of the unbonded edges that contact the nose, cheeks and chin of the user in the open configuration shown in Figures 8 and 9, is less than the perimeter of the device in the state of storage flattened by folding. In Figures 10, 11 and 12, the respiratory device 50 is shown on the face of a user, and has a cup-shaped configuration with the nasal clamp 60 shown in Figure 10, the nasal clamp 60 and the exhalation valve 64 which are shown in Figure 11, and the nasal clamp 60 'and the valve exhalation 64 which are shown in Figure 12. Such nasal clamps and exhalation valves may be equally useful on the respiratory devices shown in Figures 1-6. In the respiratory devices shown in Figures 7, 8, 10, 11 and 12 the width in the widest portion of the central portion 52 is preferably from about 160 to 220 mm, more preferably from about 175 to 205 mm, furthermore preferably from about 193 to 197 mm. The height in the highest portion of the central portion, perpendicular to the width, is preferably from about 30 to 110 mm, more preferably from about 50 to 100 mm, more preferably from about 70 to 80 mm. Preferably, the first and second members are substantially of the same width as the central portion. The depth in the deepest part of the first member is preferably about 30 to 110 mm, more preferably about 40 to 90 mm, still more preferably about 50 to 60 mm. The width in the deepest part of the second member is preferably from about 30 to 110 mm, more preferably from about 50 to 100 mm, even more preferably from about 60 to 70 mm. The depths of the first and second members may be the same or different. When the depth of the second member is greater than that of the first portion, additional protection to the chin area can be provided. By adjusting the depths of the first and second members, as well as the central portion, the adaptation of the second member under the chin can be adjusted, or the adaptation of the first portion on the nose can be adjusted so that the first portion rests along the length of the nose, or rests predominantly on the bridge of the nose. In the personal respiratory protection device shown in Figure 9, the respiratory device 50 'is configured such that the central portion 52', the first member 54 'and the second member 56', rest vertically on the face of a user with the end portions 61 and 63 of the central portion 52 'that rest on the user's nose and chin. The first member 54 'is attached to the central portion 52' at the junction 55 ', and a second member 56' is attached to the central portion 52 'at the junction 57'. Coupling means 58 ', 58"is provided for coupling, for example, a headband 59' to hold the respiratory device in place on the face of a user. Of course, the respiratory device shown in Figures 1-6 could be similarly modified by changing the location of the coupling means 18, 18 '. In such configurations, where the central portion, the first member and the second member are vertically aligned with the user's face, the distance between the coupling means is preferably from about 160 to 220 mm, more preferably from about 170 to 190 mm, for the device substantially elliptical in shape, and approximately 175 to 195 mm for the substantially rectangular device. The shape of the personal respiratory protection device flattened by folding, although generally referred to as elliptical with respect to Figures 7-12, can vary greatly. This will typically not be a regular ellipse and could, for example, even resemble a rhomboid. Various possible shapes of the folded device are shown in Figures 13 (a) to 13 (p). Thus, a quadrant of the central portion could have a joined edge configuration that resembles a right angle, or that approximates the formation of a straight line or a pattern comprising a combination of straight curves and / or lines . Preferably, such joined edge has a configuration such as a smooth curve as shown in Figure 7, more preferably, the curve has a radius of about 120 to 170 mm, more preferably about 140 150 mm. Similarly, the shape of the first and second members and the additional portions can vary considerably. Each of the first and second members must be shaped so that they can be attached to the central portion as previously described. The shape of the uncoupled edge portions of the first and second members may also vary from straight lines "to curves as desired, to achieve good adaptation to the user's face." Additional members, when present, must have a edge portion suitable for joining with the first and second edge portions, as appropriate.The shape of the unattached edge portions can go from straight lines to curved lines.For variation of the shape of the joined portions , the adaptation of the respiratory device to the face can be improved by the selected design The joints connecting the central portion with the first and second members and the additional members with the first and second members, respectively, are preferably not greater than about 15. mm in depth from the edges of the central portion, and the first member or edges of the first and second members, more preferably not greater than about 10 mm in depth, more preferably not greater than about 5 mm in depth, and may be continuous or discontinuous. The filter media or filter material useful in the present invention, which must comprise at least one of the central portion, the first member or the second member, may be comprised of a number of woven or nonwoven materials, a plurality of layers or a simple layer, with or without a thin inner or outer covering or canvas, and with or without a stiffening means. Preferably, the central portion is provided with stiffening means such as, for example, a thin woven or non-woven canvas, adhesive sticks, printing or bonding. Examples of suitable filter material include microfiber webs, fibrillated film webs, woven or nonwoven webs, (eg, air-cut or loaded staple fibers), solution-blown fibrous webs, or combinations thereof. Useful fibers for the formation of such networks include, for example, polyolefins such as polypropylene, polyethylene, polybutylene, poly (4-methyl-1-pentene) and mixtures thereof, halogen-substituted polyolefins such as those containing one or more chloroethylene units, or tetrafluoroethylene units, and which may also contain acrylonitrile units, polyesters, polycarbonates, polyurethanes, rosin-wool, glass, cellulose or combinations thereof. The fibers of the filtration layer are selected depending on the type of particulate material to be filtered. The proper selection of the fibers can also affect the comfort of the respiratory device to the user, for example, by providing smoothness or moisture control. Melt blown microfiber webs useful in the present invention can be prepared as described, for example, in Wente, Van A., "Superfine Thermoplastic Fibers" in Industrial Engineering Chemistry, Vol. 48, 1342 and subsequent ( 1956) and in Report No. 4364 of the Navel Research Laboratories, published on May 25, 1954, entitled "Manufacture of Super Fine Organic Fibers" by Van A. Wente et al. The microfibers blown into the filter media useful in the present invention preferably have an effective fiber diameter of 3 to 30 microns, more preferably about 7 to 15 microns, as calculated according to the method described in Davies., C.N., "The Separation of Airborne Dust Particles", Institution of Mechanical Engineers, London, Proceedings IB, 1952. The staple fibers may also, optionally, be present in the filtration layer. The presence of fibers cut in bulk, creped, provides a less dense network, higher, than a network consisting solely of blown microfibers. Preferably, not more than 90 percent by weight of the staple fibers, more preferably not more than 70 percent by weight, are present in the medium. Such networks containing staple fiber are described in U.S. Patent No. 4,118,531 (Hauser), which is incorporated by reference herein. The two-component staple fibers can also be used in the filtration layer or in one or more other layers of the filtration media. The bicomponent staple fibers generally having an outer layer having a lower melting point than the core portion can be used to form an elastic conformation layer bonded together at the points of intersection of the fibers, for example by heating the layer, so that the outer layer of the bicomponent fibers flows in contact with adjacent fibers that are either bicomponents or other staple fibers. The forming layer can also be prepared with binder fibers of a polyester that can flow with heat, included together with the staple fibers and after heating of the forming layer, the binder fibers melt and flow to an intersection point of the fibers. fibers where they surround the point of intersection of the fibers. After cooling, the joints develop at the intersection points of the fibers and maintain the fiber mass in the desired shape. Also, Jl materials can be applied binders such as acrylic latex or heat-activatable adhesive resins, powders, to the networks, to provide bonding of the fibers. The electrically charged fibers such as are described in U.S. Patent No. 4,215,682 (Kubik et al.), U.S. Patent No. 4,588,537 (Klasse et al.), Which are incorporated by reference herein, or by other conventional methods of electret polymerization or loading, for example, by the process of U.S. Patent No. 4,375,718 (Wadsworth et al.), or U.S. Patent No. 4,592,815 (Nakao), which are incorporated by reference herein, are particularly useful herein invention. The fibers of electrically charged fibrillated film as shown in the North American Patent • No. RE. 31,285 (van Turnhout), also incorporated by reference herein, are also useful. In general, the charging process involves fastening the material to corona discharge or pulsed high voltage. Sorbent particulate material such as activated carbon or alumina can also be included in the filtration layer. Such particle loaded networks are described, for example, in U.S. Patent No. 3,971,373 (Braun), U.S. Patent No. 4,100,324 (Anderson) and U.S. Patent No. 4,429,001 (Kolpin et al.), Which are incorporated by reference in the I presented. The masks from filter layers loaded with particles, are particularly good for protection against gaseous materials. At least one of the central portion, the first member and the second member of a respiratory device of the present invention, must comprise filtering means. Preferably, at least two of the central portion, the first member and the second member comprise filtering means and all of the central portion, the first member and the second member may comprise filtering means. The unformed portions or portions of filter media can be formed from a variety of materials. The first member can be formed, for example, from a material that provides a moisture barrier to prevent fogging of a user's glasses. The central portion can be formed of a transparent material, so that the movement of the lips by the user can be observed.

When the central portion is attached to the first and / or second members, the joint can be carried out by ultrasonic welding, adhesive bonding, stapling, sewing, by thermomechanical means, pressure or other appropriate means, and can be intermittent or continuous. Any of these means leaves the bonded area somewhat reinforced or stiffened. Such joining means are also suitable for securing the end portions of the respiratory devices shown in Figures 1-6. The respiratory devices of the present invention are preferably held in place on the face of a user by means well known to those skilled in the art, such as by adhesive or with tapes or headbands secured to the main body of the respiratory device, formed by the central portion and the first and second members of the respiratory device, or one or more additional portions of the respiratory device, in external positions, either on the outer or inner surface of the respiratory device, by means such as curls that can be integrally formed with the respiratory device shown in, for example, Figures 1 and 2, or these may be adhered to the main body of the respiratory device by means such as stamping, stapling, adhesive bonding, ultrasonic welding, sewing or other means commonly known to those skilled in the art. in the matter. Alternatively, the headbands or bands can be directly coupled to the main body of the respiratory device, using means similar to those described for the securing of the coupling medium by curl. Preferably, the headband has some degree of adjustability to effect tension against the wearer's face. Headbands or headbands useful in the present invention may be constructed from elastic polyurethane, polyisoprene, butylene-styrene copolymers such as, for example, KRATON ™ thermoplastic elastomers available from Shell Chemical Company, but may also be constructed of rubber elastic, or a stretchable coated yarn such as elastomeric fiber or LYCRAMR spandex available from DuPont Company. Also useful for the headbands or bands in the present invention are the elastomeric, activated, stretchable composites. A material of this type is a multilayer, non-adherent elastomeric laminate having at least one elastomeric core and at least one relatively non-elastomeric surface layer. The surface layer is stretched beyond its elastic limit and is relaxed with the core to form a microstructured surface layer. Microstructure means that the surface contains irregularities of peaks and valleys or bends that are large enough to be perceived by the human eye without help, to cause increased opacity on the opacity of the compound before microstructuring, and whose irregularities are small enough to To be perceived as soft or smooth for human skin. The amplification of the irregularities is required to observe the details of the microstructured texture. Such an elastomeric compound is disclosed in the US Patent Application Serial No. 07 / 503,716, filed March 30, 1990, which is incorporated by reference herein. The non-elastic webs useful in the present invention include, for example, non-woven materials formed by wet spread, and dry spread, and consist of rayon, polyester or similar fibers, fused networks of fused together, calendered, of polypropylene, polyethylene or polyester, and reinforced paper. The bands can be either tied, locked or stretched such that the bands surround the user's head, putting the face mask in sealing engagement with the user's face. Alternative band designs may also include constructions of open curls or closed curls to encircle the wearer's head or curls or loops over the wearer's ears. U.S. Patent No. 5,237,986 (Seppala et al.) Discloses a headband assembly that makes it possible for the mask to be easily and quickly applied, and provides temporary storage during periods of non-use. A nasal clamp useful in the respiratory device of the present invention can be made, for example, of a soft, inactive, collapsible band of metal such as aluminum or plastic-coated wire, and can be shaped to fit the device comfortably to the face of the patient. an user. Particularly preferred is a non-linear nasal clamp, configured to extend over the bridge of a user's nose, having inflections positioned along the clamp section to provide fins that help provide a comfortable fit of the mask in the nose and in the area of the cheeks, as shown in Figure 12. A nasal clamp can be secured to the respiratory device by an adhesive, for example, a pressure sensitive adhesive, or a hot melt, liquid adhesive. Alternatively, the nasal clamp can be encapsulated in the body of the respiratory device, or this can be maintained between the body of the device and a fabric or foam that is mechanically or adhesively coupled thereto. In one embodiment of the invention, as shown in Figure 6 or Figure 12, the nasal clamp is placed on the outside of the first member and a piece of foam (not shown) is placed on the inside of the first member of the respiratory device, in alignment with the nasal clamp. The respiratory device may also include an optional exhalation valve, typically a diaphragm valve, which allows for easy exhalation of air by the user. An exhalation valve having an extremely low pressure drop during exhalation for the mask is described in U.S. Patent No. 5,325,892 (Japuntich et al.) Which is incorporated by reference herein. Many exhalation valves of other designs are well known to those skilled in the art. The exhalation valve is preferably secured to the central portion, preferably near the middle part of the central portion, by sonic welding, adhesive bonding, mechanical locking or the like. The respiratory device may optionally have a face shield attached to the upper edge or outer portions of the respiratory device. Typical facepieces are described, for example, in U.S. Patent No. 2,762,368 (Bloomfield) and U.S. Patent No. 4,944,294 (Borek, Jr.), Which are incorporated by reference herein. Also useful is the type of face shield 72 described in U.S. Patent No. 5,020,533 (Hubbard et al.) And shown in Figure 14, which has a cut 73 near the center of the shield to facilitate the conformation of the respirator 71 and the protector 72 to the user's face, with a darkened strip 74 on the upper edge of the device 71, to reduce reflection, also incorporated by reference herein. In addition, facial seals that minimize air leakage between the device and the face can also optionally be used with the respiratory device of the present invention. Typical facial seals are described, for example, in U.S. Patent No. 4,600,002 (Maryyanek et al.), U.S. Patent No. 4,688,566 (Boyce), and U.S. Patent No. 4,827,924 (Japuntich), which discloses a ring of elastomeric material soft 76 as shown in Figure 15 on respiratory device 75, each of which is incorporated by reference herein, as well as Canadian Patent No. 1,296,487 (Yard). Also, neck coverages which protect the neck area of, for example, spilled liquids, with the respiratory devices of the present invention can be utilized. Typical coats for neck are described, for example, in U.S. Patent No. 4,825,878 (Kuntz et al.), North American Patent No. ,322,061 (Brunson), and North American Patent of Design No. Des. 347.090 (Brunson), which are incorporated by reference herein. Figure 16 shows a typical coverage for neck 78 on the respiratory device 77. The respiratory devices of the present invention can be sterilized by any standard method, such as gamma radiation, exposure to ethylene oxide, or autoclaving, although these processes They can affect any load that has been provided to the device. Personal folding-flattened respiratory protection devices of the present invention can be prepared by forming a flat central portion having at least a first edge and a second edge, and coupling a first flat member to the central portion in the first edge of the central portion, with a folding, joining or sewing. The edge with folding, joining or stitching of the first portion, is substantially coextensive with the first edge of the central portion. A second planar member is coupled to the central portion at the second edge of the central portion, with a folding, joining or sewing. Again, the folding edge or the edge or seam of the second member is substantially coextensive with the second edge of the central portion. At least one of the central portion, the first and second members contain filtering means. The folding flattened respiratory devices shown in Figures 1-6 can be produced by forming a rectangular sheet of filtration means, folding a first long edge towards the center of the sheet to form a first member, folding the second long edge towards the center of the sheet, to form a second member and sealing the non-folded edges. The process may optionally include additional members coupled to the first and second members at their non-folded edges, through additional folds or joints. The folding flattened respiratory devices shown in Figures 7-12 can be produced by forming a first elliptical sheet of filter media having two edges, forming a second elliptical sheet of filter media having two edges, at least one side of each sheet having a common shape, joining the common shaped edges, folding the unbonded edge of the second sheet towards the joined edge, forming a third elliptical sheet of filter media having two edges, at least one edge of the edges which has a common shape with the unbonded edge of the first sheet, placing the third sheet on the second sheet and joining the common shaped edges of the first and third sheets. Each process is suitable for high speed production methods, and may comprise additional steps as necessary for the coupling of headbands, nasal clamps, and other typical components for respiratory device. Figures 17-20 are schematic illustrations of a preferred high-speed production process, 120, for the manufacture of pleated flattened breathing devices as shown in Figures 7-12. A portion of foam 122 is preferably positioned between an inner cover network 124 and a filtration means 126. In an alternative embodiment, the optional foam portion 122 and / or the nose clamp 30 can be placed on an outer surface of either a the internal coverage network 124 or the external coverage network 132. A reinforcement material 128 is optionally placed close to the center on the filter means 126. A nose clamp 130 is optionally placed along one edge of the filtration means 126 next to the reinforcement material 128, in a station 130a for applying the nasal clamp. The filtration means 126, an optional reinforcement material 128 and the optional nose clamp 130 are covered by an outer cover network 132 to form a network assembly 134 shown in section (see Figure 18). The network assembly 134 can be held together by surface forces, electrostatic forces, thermal bonding, an adhesive or any other well-known, appropriate means. An exhalation valve 136 is optionally inserted into the network assembly 134 in a valve station 136a. The valve station 136a preferably forms a hole close to the center of the assembly 134 of the network. The edges of the hole can be sealed to minimize excess network material. Valve 136 may be retained in the orifice by welding, adhesive, snap fit, clamping, snap mounting or some other appropriate means. Exemplary respiratory devices with exhalation valves are illustrated in Figures 11 and 12. As shown in Figure 9, the network assembly 134 can be welded and trimmed along the weld for facial adjustment and finishing lines of edge 133, 135 in the facial adjustment station 138. The excess net material 140 is removed, and the trimmed net assembly 142 is advanced to the folding station 144. The folding station 144 folds the first and second members 143, 148 inward, towards the center of the cut-off network assembly 142, along the folding lines 150, 152, respectively, to form a blanks blank 155 of the folded device, illustrated in Figure 20. blank 155 of the folded device can be welded along the edges 158, 160 in the headband finishing coupling station 154a, to form a strip of respiratory devices 156 from and which excess material can be removed beyond the bond lines. The welding line or junction 160 is adjacent to the weld for facial fit or adjustment and to the edge finish lines 133. The face fit weld and the edge finish line 135 are shown in dashed lines, since it is below of the first member 146. The headband material 154 forming a headband 161 is placed on the blank 155 of the folded device, along a band track "H" extending between the sites coupling 162, 164 left and right for headband. The headband 161 is preferably coupled to the blank of the device 155 at the left and right coupling sites 162, 164 of the headband. Since the blank 155 of the device is substantially planar during the manufacturing process 120, the "H" track of the headband is an axis that substantially intersects the left and right coupling sites 162, 164. When the band for head is the preferred material described in the US Patent Application Serial No. 07 / 503,716, filed on March 30, 1990, it will be understood that it is possible to activate or partially activate the material 154 of the headband before, during or after application to the blank piece 155 of the respiratory device. A preferred method is to activate the material 154 of the headband just prior to application by the selective clamping or holding of the headband material still inactivated between the adjacent clamps, elongating it to the desired amount, by placing the material 154 of the head. headband activated on the blank 155 of the device, and coupling the inactivated end portions of the material 154 of the headband to the blank 155 of the device. Alternatively, the material 154 of the inactivated headband can be placed on the blank 155 of the device, coupled at the ends as discussed herein, and then activated prior to packaging. Finally, the material 154 of the headband can remain inactive until it is activated by the user. A longitudinal dotted line "S" may be optionally formed either before, during or after the coupling of the headband material 154 to the blank 155 of the device at the finishing and headband coupling station., 154a, to create a headband of multiple parts. The edges 166, 168 of the blank 155 of the device adjacent to the coupling sites 162, 164 of the left and right headband can be either divided to form discrete or perforated breathing devices to form a strip of respiratory devices 167 (see Figure 21). The finished breathing devices 167 are packaged in the packaging station 169. Figure 21 illustrates a strip of folding flattened breathing devices 167, manufactured according to the process of Figures 17-20. The edges 166, 168 are preferably perforated, so that the respiratory device 167 can be packaged in a roll or spool. A portion of the headband 161 at the edges 166, 168 has been removed by the drilling process. In an alternative embodiment, the headband 161 extends continuously beyond the edges 166, 168. Figure 20 illustrates the headband 161 of multiple parts coupled to the back of the respiratory device 167, although this could be engaged in any of the configurations described herein. It will be understood that either a single-part or multi-part head band 161 may be coupled to either side of the respiratory device 167, either a detachment or shear configuration, although shearing is preferred. When other types of headband material are used, the headband material is applied to the desired length in the respiratory device flattened by folding, finishing, finishing, and coupled to the left and right sites 162, 164 for coupling the headband. The following examples further illustrate this invention, but the particular materials, sizes and forms thereof in these examples, as well as other conditions and details should not be considered as unduly limiting this invention. Examples The personal devices for respiratory protection of the present invention are further described by way of the non-limiting examples described below.

Example 1 Two sheets (350 mm x 300 mm) of electrically charged molten blown polypropylene microfibers were placed one on top of the other to form a layered network having a basis weight of 100 g / m2 , an effective fiber diameter of 7 to 8 microns, and a thickness of approximately 1 mm. An outer shell layer of a polypropylene network of fused, lightweight filaments (350 mm x 300 mm; 50 g / m2, Type 105OB1UO0, available from Don and Low Nonwovens, Forfar, Scotland, United Kingdom) was placed in contact with one side of the network in microfiber layers. A strip of the polypropylene support mesh (380 mm x 78 mm, 145 g / m2, Type 5173, available from Intermas, Barcelona Spain) was placed across the remaining surface of the microfibers at approximately 108 mm from a long edge of the layered microfiber network, and 114 mm from the other long edge of the layered microfiber network, and extending over the edges of the microfiber surface. An inner cover sheet (350 mm x 300 mm, 23 g / m2, LURTASILMR 6123, available from Spun UK, Derby, England, United Kingdom) was placed on the upper part of the support mesh and the microfiber net exposed remainder. The 5-layer construction was then ultrasonically bonded into a roughly rectangular shape approaching the layered construction to provide the joints that held the construction in layers together on its perimeter, forming an upper edge, a lower edge and two side edges. The layers were also bonded together along the long edges of the support mesh. The length of the construction joined in this way, joined in parallel to the upper and lower edges, was 188 mm; and the width, measured parallel to the lateral edges, was 203 mm. The edges of the strip of the support mesh were placed 60 mm from the top edge of the layered construction, and 65 mm from the bottom edge of the construction. The excess material beyond the periphery of the joint was removed, leaving portions beyond the joining line at the side edges, close to the center line of the support mesh, 50 mm long x 20 mm wide to form the coupling means of the headband. The upper edge of the layered construction was longitudinally folded close to the nearest edge of the support mesh, to form an upper fold, such that the inner cover made contact with itself by a distance of 39 mm from the upper fold, to form a first member, forming the remaining 21 mm of the layered construction, an additional portion. The lower edge of the layered construction was folded longitudinally close to the closest edge of the support mesh, to form a lower fold, such that the inner cover contacted itself by a distance of 39 mm, to form a second member, the remaining 26 mm forming an additional portion. The inner cover layer of the additional portions was then brought into contact with one another. The contact portions of the central portion, lying between the upper and lower folds, the first and second members, were sealed at their side edges. A malleable nasal clamp approximately 5 mm wide x 140 mm long was. coupled to the outer surface of the additional portion coupled to the first member, and a strip of the nose foam of approximately 15 mm x 140 mm in length was coupled to the internal surface of the additional portion, substantially aligned with the nose clamp. The additional portions were folded, such that the outer covers of each made contact with the outer cover of the first and second members, respectively. The free ends of the layered construction left to form the coupling means for the headband were folded to the joined edge of the layered construction and joined to form loops or curls. The elastic of the headband was entangled through the turns to provide means for securing the respiratory device thus formed to the face of a wearer.

Example 2 The first and second sheet constructions in layers (350 mm by 300 mm) were prepared as in Example 1, except that the support mesh was omitted. A curvilinear joint was formed along one long edge of each sheet, and the excess material beyond the convex portion of the joint was removed. A third layer sheet construction was prepared as in Example 1, except that each of the five layers was substantially coextensive. The first layer sheet construction was placed on top of the third layer sheet construction with the covers in contact. The first and third leaf constructions were joined together using a curvilinear joint near the unbonded long edge of the first sheet construction to form a first member of the elliptical respiratory device, having a width of 165 mm and a depth of 32 mm. The radius of each of the curvilinear joints was 145 mm.

The edge of the first sheet construction not attached to the third sheet was folded back towards the edge of the first sheet which was attached to the third sheet. The second sheet construction was placed on top of the first folded sheet, and partially covered the third sheet. The second and third sheet constructions were joined together using a curvilinear joint to form a second elliptical member of the respiratory device, starting from the second leaf, having a width of 165 mm and a depth of 32 mm, and a central elliptical portion. of the respiratory device having a width of 165 mm and a height of 64 mm, from the third sheet construction. The material outside the elliptical portions was removed. The first and second members were folded away from the central portion. A malleable aluminum nasal clamp was coupled to the outer surface of the periphery of the first member, and a strip of the nasal foam was attached to the inner surface in substantial alignment with the nasal clamp. The coupling means for the headband were coupled at the points where the junctions between the central portion and the first and second members meet, and the elastic of the headband was wound around the coupling means to form a respiratory device ready for a user to put it on. The various modifications and alterations of this invention will be apparent to those skilled in the art, without departing from the spirit and scope of this invention, and this invention should not be restricted to that described herein, for illustrative purposes. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Having described the invention as above, property is claimed as contained in the following:

Claims (38)

1. A personal device for respiratory protection, characterized in that it comprises: a) a flat central portion having first and second edges, b) a first flat member joined to the first edge of the central portion, either through a folding line, seam , welding or joining, said folding, joining, welding or sewing of the first member being substantially coextensive with the first edge of the central portion, and c) a second flat member attached to the second edge of the central portion, either through a line of folding, sewing, welding or joining, said folding, joining, welding or sewing of the second member being substantially coextensive with the second edge of the central portion, at least one of the central portion and the first and second members being formed starting from filter means, and the device is capable of being flattened by folding for storage with the first and second members that are in co At least partial face-to-face contact with a common surface of the central portion and, during use, is capable of forming a cup-shaped air chamber over the user's nose and mouth, with the unattached edges of the portion central and the first and second members of the unattached edges are adapted to contact and be secured to the nose, cheeks and chin of the user, and the outer limit of the unbonded edges which are adapted to contact the nose, cheeks and chin of the user, being less than the perimeter of the device in the state of storage flattened by folding.

2. The respiratory device according to claim 1, characterized in that the central portion is substantially rectangular.

3. The respiratory device according to claim 2, characterized in that the central portion is approximately 160 to 220 mm wide and approximately 30 to 110 mm high.

4. The respiratory device according to claim 2, characterized in that the first member is rectangular.

5. The respiratory device according to claim 4, characterized in that the first member is approximately 160 to 220 mm wide and approximately 30 to 110 mm deep.

6. The respiratory device according to claim 2, characterized in that the second member is rectangular.

7. The respiratory device according to claim 6, characterized in that the second member is approximately 160 to 220 mm wide and approximately 30 to 110 mm deep.

8. The respiratory device according to claim 2, characterized in that the device further comprises an additional member coupled to the first member by a folding, sewing, welding or joining.

9. The respiratory device according to claim 8, characterized in that the additional member is rectangular.

10. The respiratory device according to claim 9, characterized in that the additional member is approximately 160 to 220 mm wide and approximately 5 to 95 mm deep.

11. The respiratory device according to claim 2, characterized in that the device further comprises an additional member coupled to the second member by means of a folding, sewing, welding or joining.

12. The respiratory device according to claim 11, characterized in that the additional member is rectangular.

13. The respiratory device according to claim 12, characterized in that the additional member is approximately 160 to 220 mm wide and approximately 3 to 95 mm deep.

14. The respiratory device according to claim 1, characterized in that the central portion is substantially elliptical in shape.

15. The respiratory device according to claim 14, characterized in that the central portion is approximately 160 to 220 mm wide and approximately 30 to 110 mm high.

16. The respiratory device according to claim 14, characterized in that the first member is substantially elliptical in shape.

17. The respiratory device according to claim 16, characterized in that the first member is approximately 160 to 220 mm in width and approximately 30 to 110 mm in height.

18. The respiratory device according to claim 14, characterized in that the second member is substantially elliptical in shape.

19. The respiratory device according to claim 18, characterized in that the second member is approximately 160 a 220 mm wide and approximately 30 to 110 mm high.

20. The respiratory device according to claim 1, characterized in that the device is a multi-layer construction.

21. The respiratory device according to claim 20, characterized in that at least one layer is microfibers blown in molten form.

22. The respiratory device according to claim 21, characterized in that the blown microfibers in molten form are electrically charged.

23. The respiratory device according to claim 21, characterized in that the layer of blown microfibers in molten form is covered by a layer of fused filaments, of outer shell.

24. The respiratory device according to claim 21, characterized in that the layer of blown microfibers in molten form is covered by a layer of filaments fused together, of inner cover.

25. The respiratory device according to claim 20, characterized in that at least the central portion has a stiffening layer.

26. The respiratory device according to claim 1, further characterized in that it comprises a nasal clamp in the first member.

27. The respiratory device according to claim 1, further characterized in that it comprises an exhalation valve.

28. The respiratory device according to claim 27, characterized in that the exhalation valve is located in the central portion of the respirator.

29. The respiratory device according to claim 1, further characterized by comprising head band coupling means.

30. The respiratory device according to claim 1, further characterized in that it comprises a headband.

31. The respiratory device according to claim 30, characterized in that the headband comprises an elastomeric composite material, activated by stretching.

32. The respiratory device according to claim 1, further characterized in that it comprises a face shield.

33. The respiratory device according to claim 1, further characterized in that it comprises a facial seal.

34. The respiratory device according to claim 1, further characterized by comprising a neck covering.

35. A process for the production of personal respiratory protection devices for providing respiratory protection to a user, characterized in the process because it comprises: a) the formation of a flat central portion, the central portion having at least a first edge and a second edge; b) coupling a first flat member to the central portion at the first edge of the central portion, with a folding, joining, welding or sewing, said folding, joining, welding or sewing the edge of the first member being substantially coextensive with the first edge of the central portion; c) coupling a second flat member to the central portion at the second edge of the central portion, with a folding, joining, welding or sewing, said folding, joining, welding or sewing the edge of the second member being substantially coextensive with the second edge of the central portion; with the proviso that at least one of the central portion, the first member and the second member comprises filtering means, and the device is capable of being flattened by folding for storage and, during use, is capable of forming a chamber of cup-shaped air over the nose and mouth of the user, and unbonded edges of the central portion, the first member and the second member adapted to make contact and be secured to the nose, cheeks and chin of the patient. user, and the outer limit of the unbonded edges which are adapted to make contact with the nose, cheeks and chin of the user, which is less than the perimeter of the device in the storage state flattened by folding.

36. A process for producing personal respiratory protection devices according to claim 2, characterized in that it comprises the steps of forming a rectangular sheet of filtration means, the folding of a first long edge toward the center of the sheet, to form a first member , the folding of the second long edge towards the center of the sheet to form a second member, and the sealing of the unfolded edges.

37. A process for preparing personal respiratory protection devices according to claim 14, characterized in that it comprises the formation of a first elliptical sheet of filtration means having two edges, forming a second elliptical sheet of filter media having two edges, at less one side of each sheet has a common shape, joining the common shaped edges, folding the unbonded edge of the second sheet towards the joined edge, forming a third elliptical sheet of filtration means having two edges, at least one edge of which has a common shape with the unbonded edge of the first sheet, placing the third sheet on the second sheet, and joining the common shaped edges of the first and third sheets.

38. A process for preparing a personal respiratory protection device, flattened by folding, characterized the process because it comprises: the placement of an internal cover network and an external cover network on the first and second sides of the filter means, respectively, for form a network assembly; the welding of the welding finishing lines and adaptation edge to the face; the elimination of excess network material; folding the first and second portions inward toward the center of the trimmed net assembly to form a blank piece of folded face mask. SUMMARY OF THE INVENTION Personal respiratory protection devices are flattened by folding. The devices have a flat central portion having first and second edges, a first flat member attached to the first edge of the central portion, either through a folding, sewing, welding or joining line, said folding, joining, welding or stitching of the first member, substantially coextensive with the first edge of the central portion, and a second flat member joined to the second edge of the central portion, either through a folding, sewing, welding or joining line, the folding being , joining, welding or sewing the second member, substantially coextensive with the second edge of the central portion. At least one of the central portion and the first and second members are formed of filter means. The device is capable of being flattened by folding for storage, with the first and second members being in at least partial face-to-face contact with a common surface of the central portion and, during use, capable of forming a chamber of cup-shaped air over the nose and mouth of the user, with the unbonded edges of the central portion and the first and second members adapted to contact and be secured to the nose, cheeks and chin of the user. The outer limit of the unbonded edges which are adapted to come into contact with the user's nose, cheeks and chin, is less than the perimeter of the device in the storage state flattened by folding. Processes are also provided for the preparation of such devices.