Unitary respirator with molded thermoset elastomeric elements

Abstract

A respiratory protection composite facepiece is disclosed and includes a polymeric rigid facepiece body portion having a first surface and a second surface and a silicone sealing facepiece element chemically bonded at least one of the first surface or the second surface. The first and second surfaces can be opposing major surfaces. A second silicone element is chemically bonded to at least one of the first surface or the second surface. Methods of making the same are also disclosed.

1 . A respiratory protection composite facepiece comprising:
 a polymeric rigid facepiece body portion having a first surface and a second surface;   a silicone sealing facepiece element chemically bonded to at least one of the first surface or the second surface; and   a second silicone element chemically bonded to at least one of the first surface or the second surface.   
   
   
       2 . A respiratory protection composite facepiece according to  claim 1 , wherein the polymeric rigid facepiece body portion further comprises an inhalation valve or an exhalation valve and the second silicone element forms a diaphragm for the inhalation valve or the exhalation valve. 
   
   
       3 . (canceled) 
   
   
       4 . A respiratory protection composite facepiece according to  claim 1 , wherein the polymeric rigid facepiece body portion further comprises a speaking port and the second silicone element forms a diaphragm for the speaking port. 
   
   
       5 . A respiratory protection composite facepiece according to  claim 1 , wherein the silicone sealing facepiece element is chemically bonded to the first surface and the second surface. 
   
   
       6 . A respiratory protection composite facepiece according to  claim 1 , wherein the polymeric rigid facepiece body portion comprises a plurality of apertures extending through the polymeric rigid facepiece body portion and the silicone sealing facepiece element interpenetrates at least a portion of the apertures. 
   
   
       7 . A respiratory protection composite facepiece according to  claim 1 , wherein the polymeric rigid facepiece body portion comprises a thermoplastic polymer and the silicone sealing facepiece element and the second silicone element is a thermoset polymer and the thermoset polymer chemically bonds directly onto the thermoplastic polymer. 
   
   
       8 . A respiratory protection composite facepiece according to  claim 1 , wherein the polymeric rigid facepiece body portion further comprises an inhalation valve and the second silicone element forms a gasket surrounding the inhalation valve. 
   
   
       9 . A respiratory protection composite facepiece according to  claim 1 , wherein the second silicone element forms at least a portion of one or more straps configured to secure the respiratory protection composite facepiece to a user's head. 
   
   
       10 . A respiratory protection composite facepiece comprising:
 a polymeric rigid facepiece body portion having a first surface and a second surface and a inhalation port;   a silicone sealing facepiece element chemically bonded to at least one of the first surface or the second surface and forming a gasket about the inhalation port.   
   
   
       11 . A respiratory protection composite facepiece according to  claim 10 , wherein the silicone sealing facepiece element is chemically bonded to the first surface and the second surface. 
   
   
       12 . A respiratory protection composite facepiece according to  claim 10 , wherein the polymeric rigid facepiece body portion comprises a plurality of apertures extending through the polymeric rigid facepiece body portion and the silicone sealing facepiece element interpenetrates at least a portion of the apertures. 
   
   
       13 . A method of forming a respiratory protection composite facepiece comprising:
 overmolding liquid silicone onto a polymeric rigid facepiece body portion having a first surface and a second surface, the liquid silicone in contact with at least one of the first surface or the second surface; and   solidifying the liquid silicone to form a silicone sealing facepiece element that chemically bonds to one of the first surface or the second surface, and a second silicone element chemically bonded to at least one of the first surface or the second surface, forming a respiratory protection composite facepiece.   
   
   
       14 . A method according to  claim 13 , wherein the polymeric rigid facepiece body portion further comprises an inhalation valve or an exhalation valve and the solidifying step forms a second silicone element diaphragm for the inhalation valve or the exhalation valve. 
   
   
       15 . A method according to  claim 13 , wherein the solidifying step solidifies the liquid silicone to form a silicone sealing facepiece element that chemically bonds to the first surface and the second surface. 
   
   
       16 . A method according to  claim 13 , wherein the polymeric rigid facepiece body portion comprises a plurality of apertures extending through the polymeric rigid facepiece body portion and the overmolding step interpenetrates liquid silicone into at least a portion of the apertures to form the silicone sealing facepiece element. 
   
   
       17 . (canceled) 
   
   
       18 . A method according to  claim 13 , wherein the solidifying step second silicone element forms at least a portion of one or more straps configured to secure the respiratory protection composite facepiece to a user's head. 
   
   
       19 . A method according to  claim 14 , further comprising attaching a chemical or particulate filtration cartridge to the inhalation valve. 
   
   
       20 . A method of forming a respiratory protection composite facepiece comprising:
 overmolding liquid silicone onto a polymeric rigid facepiece body portion having a first surface and a second surface, the liquid silicone in contact with at least one of the first surface or the second surface; and   solidifying the liquid silicone to form a silicone sealing facepiece element that chemically bonds to one of the first surface or the second surface, and forming a gasket about the inhalation port.   
   
   
       21 . A method according to  claim 20 , wherein the solidifying step solidifies the liquid silicone to form a silicone sealing facepiece element that chemically bonds to the first surface and the second surface. 
   
   
       22 . A method according to  claim 20 , wherein the polymeric rigid facepiece body portion comprises a plurality of apertures extending through the polymeric rigid facepiece body portion and the overmolding step interpenetrates liquid silicone into at least a portion of the apertures to form the silicone sealing facepiece element.