Flat-folded personal respiratory protection devices and process for preparing same

Fold-flat personal respiratory protection devices (10,50) are provided. The devices have a central panel (12,52) having first and second edges, a first panel (14,54) joined to the first edge of the central panel through either a fold-line (15,55), seam, weld or bond, said fold, bond, weld or seam of the first panel being substantially coextensive with said first edge of said central panel, and a second panel (16,56) joined to the second edge of the central panel through either a fold-line, seam, weld or bond, the fold, bond, weld or seam (17,57) of the second panel being substantially coextensive with said second edge of said central panel. The central and first and second panels are formed from filter media. The device is capable of being folded flat for storage with the first and second panels being in at least partial face-to-face contact with a common surface of the central panel and, during use, is capable of forming a cup-shaped air chamber over the nose and mouth of the wearer with the unjoined edges of the central portion and first and second panels adapted to contact and be secured to the nose, cheeks and chin of the wearer.