US Patent 7989372 Molded respirator comprising meltblown fiber web with staple fibers

A molded respirator and method of making are disclosed, wherein the molded respirator is made from a porous nonwoven web containing meltblown fibers and staple fibers. The meltblown fibers may be present as a bimodal mixture of microfibers and mesofibers, and comprise an intermingled mixture with staple fibers further intermingled therein. The molded respirator may also contain at least one secondary filtration layer.