Surgical face mask, including reusable masks, with filtered inhalation and exhalation valves

Abstract

Face masks that can be used, for example, in medical and surgical procedures, including both completely or partially disposable and reusable masks, that can be custom fitted to the wearer, and which can include one or more filtering inhalation and exhalation valves and/or compartments allowing for separated filtering of inhalation and exhalation gases. Some embodiments include systems, methods and kits for reducing contaminants in an inhalation and exhalation flow stream.

1 . A face mask comprising:
 a generally cup shaped mask body comprising an interior surface, an opening having a peripheral edge shaped to generally follow a contour of a human face extending around the nasal and oral areas, a recess shaped to receive oral and nasal features of a human face, and an exterior surface opposite the interior surface;   a first semi-pliable or metal strip on the exterior surface of the peripheral edge;   a second semi-pliable or metal strip on the interior surface of the peripheral edge;   a heat-activated thermoplastic member coupled to the peripheral edge, wherein the heat-activated thermoplastic member extends around at least a portion of the peripheral edge and extends over the first semi-pliable or metal strip, over the second semi-pliable or metal strip and onto the exterior and interior surfaces of the mask body, respectively;   an exhalation valve disposed on the mask body and having a first orifice that allows exhaled air to pass from an interior gas space to an exterior gas space during an exhalation; and   at least one inhalation valve disposed on the mask body having a second orifice that allows inhaled air to pass from an exterior gas space to an interior gas space during an inhalation, wherein said at least two valves each comprise a filter element; and   at least one retention member attached to said mask body.   
     
     
         2 . The face mask of  claim 1 , wherein said heat-activated thermoplastic member extends for the entirety of said peripheral edge. 
     
     
         3 . (canceled) 
     
     
         4 . The face mask of  claim 1 , wherein said heat-activated thermoplastic member comprises ethylene vinyl acetate. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . The face mask of  claim 1 , further comprising at least one visco-elastic member disposed on the interior of said mask body at a location alignable with a position selected from the nasal bridge of a user, and the lower chin of a user. 
     
     
         10 . The face mask of  claim 1 , further comprising a generally cup shaped insert comprising an opening and a recess, the recess shaped to receive oral and nasal features of a human face, and said insert is adapted to be inserted into said mask body. 
     
     
         11 . The face mask of  claim 10 , wherein said insert further comprises at least one exhalation valve opening disposed therein where said exhalation valve is located thereon, and at least one inhalation valve opening disposed therein where said inhalation valve is located thereon. 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . A reusable surgical face mask of a generally cup shaped design constructed of soft plastic copolymer and, comprising:
 a mask body comprising one or more receptacles;   at least one reusable or replaceable or both filtered exhalation valve, wherein the at least one exhalation valve is configured to fit into a receptacle in the mask body;   at least one reusable or replaceable filtered inhalation valve wherein the at least one inhalation valve is configured to fit into a receptacle in the mask body;   a heat-activated thermoplastic member coupled to a peripheral edge of the mask, wherein the heat-activated thermoplastic member extends around the entire peripheral edge of the mask and onto an exterior and an interior surface of the mask body, wherein the heat-activated member comprises EVA, PO or a combination thereof; and   a passive/active adjustable strap system for securing the mask to the user's head.   
     
     
         18 . The mask of  claim 17 , wherein the thermoplastic polymer is EVA, PO or a combination thereof. 
     
     
         19 . The mask of  claim 17 , wherein the mask body comprises a styrene-based thermoplastic elastomeric compound. 
     
     
         20 . (canceled) 
     
     
         21 . The mask of  claim 17  further comprising a first semi-pliable or metal strip on an exterior surface of the peripheral edge, wherein the heat-activated thermoplastic member extends around at least a portion of the peripheral edge, and extends over the first semi-pliable or metal strip and onto the interior and exterior surfaces of the mask body. 
     
     
         22 . The mask of  claim 21  further comprising a second semi-pliable or metal strip on an exterior surface of the peripheral edge, wherein the heat-activated thermoplastic member extends over the first semi-pliable or metal strip, over the second semi-pliable or metal strip, and onto the interior and exterior surfaces of the mask body.