Respiratory facepiece and method of making a facepiece using separate molds

• US 20050109343A1
• Filed: 11/21/2003
• Published: 05/26/2005
• Est. Priority Date: 11/21/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Flanningan, Paul J., Maxa, Steven J.
• Granted Patent: US 7,650,884 B2
• Time in Patent Office: Days
• US Class Current: 128/206.170
• CPC Class Codes: A62B 18/025 Halfmasks A62B23/02 takes precedence; surgical face masks A41D13/11
• CPC Class Codes: A62B 18/08 Component parts for gas-masks or gas-helmets, e.g. windows, straps, speech transmitters, signal-devices eye-pieces for protective goggles A61F9/02; composition of materials for the windows or other transparent parts A62D7/00
• CPC Class Codes: B29C 45/0062 Joined by injection moulding
• CPC Class Codes: B29C 45/1676 using a soft material and a rigid material, e.g. making articles with a sealing part
• CPC Class Codes: B29L 2031/4835 Masks

Abstract

A facepiece insert (16) that has a fluid communication component (30, 32) non-integrally joined to a supporting portion (34). The insert can be made by (a) providing at least one supporting portion (34) of a facepiece insert (16); (b) providing at least one fluid communication component (30, 32) separately from the supporting portion (34) of the facepiece insert (16); and (c) securing the at least one fluid communication component (30, 32) to the at least one supporting portion (34).

Claims

1. A method of making a facepiece insert that has at least one fluid communication component, which method comprises:

(a) providing at least one supporting portion of a facepiece insert;

(b) providing at least one fluid communication component separately from the supporting portion of the facepiece insert; and

(c) securing the at least one fluid communication component to the at least one supporting portion.

2. A method of making a respiratory mask body, which method comprises the steps of claim 1 and further comprises:

(d) securing a compliant face-contacting member to the facepiece insert,

3. A method of making a respiratory mask, which method comprises the steps of claim 2 and further comprises:

(e) securing a harness to the mask body.

4. The method of claim 3, further comprising providing at least one filter cartridge that is capable of being attached to the at least one fluid communication component.

5. The method of claim 1, wherein the at least one fluid communication component is a critical tolerance component.

6. The method of claim 2, wherein the at least one fluid communication component is a critical tolerance component.

7. The method of claim 3, wherein the at least one fluid communication component is a critical tolerance component.

8. The method of claim 1, wherein the at least one supporting portion of the facepiece insert and the at least one fluid communication component are made from similar polymeric materials and are fused together.

9. The method of claim 1, wherein the at least one fluid communication component has a tolerance of less than 0.15 millimeters.

10. The method of claim 1, wherein the at least one fluid communication component has a tolerance of less than 0.1 millimeters.

11. The method of claim 1, wherein the at least one fluid communication component has a tolerance of less than 0.05 millimeters.

12. The method of claim 1, wherein the supporting portion of the facepiece insert has a tolerance of about 0.16 to 0.3.

13. A facepiece insert that comprises:

(a) a supporting portion; and

(b) a fluid communication component that is non-integrally joined to the supporting portion

14. A respiratory mask body that comprises the facepiece insert of claim 13, and further comprises a compliant face contacting member that is non-integrally joined to the supporting portion of the facepiece insert,

15. The respiratory mask body of claim 14, wherein the fluid communication component has a tolerance of 0. 15 or less, and wherein the supporting portion has a tolerance of about 0.16 mm or greater.

16. A respiratory mask, that comprises the mask body of claim 14, and farther includes a harness for supporting the mask body over a person'"'"'s nose and mouth

17. A respiratory mask, that comprises the mask body of claim 14, and further includes a filter cartridge for supporting the mask body over a person'"'"'s nose and mouth.

18. The respiratory mask of claim 16, wherein the fluid communication component comprises part of an inhalation valve.

19. The respiratory mask of claim 16, wherein the fluid communication component comprises part of an exhalation valve.

20. A respiratory mask of claim 16, wherein the fluid communication component has a tolerance of 0.15 or less, and wherein the supporting portion has a tolerance of about 0.16 to 0.3 mm.

21. The respiratory mask of claim 16, wherein the supporting portion and the fluid communication component are fused together.

22. A respiratory mask that comprises:

(A) a mask body that includes;

(1) a facepiece insert that includes;

(a) a supporting portion;

(b) at least one fluid communication component that is non-integrally joined to the supporting portion and that is a critical tolerance component; and

(2) a compliant face-contacting member that is non-integrally joined to the supporting portion of the facepiece insert; and

(B) a harness for supporting the mask body at least over a person'"'"'s nose and mouth.

23. The respiratory mask of claim 23, further comprising at least one filter cartridge that is secured to the mask body at a location where the fluid communication component resides.