DESCRIPTION
FIELD OF INVENTION:
The invention generally relates to protective or safety face masks. The invention more precisely relates to a reusable face mask.

BACKGROUND OF THE INVENTION:
Face mask is an instrumental tool in protecting against respiratory and other diseases. It filters the air from contaminants and provides clean air to the user.
Many face masks being used today are disposable. This results in unnecessary escalation of cost of the masks, in addition to creating avoidable waste. If we consider the cost of masks fitted with an exhalation valve, it goes prohibitively high and results in a decrease of adoption of sufficiently safe masks. It also results in a tendency of overuse of the masks, thereby promoting a risk of false perception of safety by the user.
The actual filtering action can also be provided by a smaller filtering pad, fitted in a larger reusable mask. The filter pad will be relatively less expensive, thereby encouraging the user to replace it at the recommended duration. The mask can feature an exhalation valve built-into its main body. This will also reduce the recurring cost, because in existing disposable masks, the exhalation valve, which is not defective, is also discarded with the mask. In addition, it will be possible to sterilize the body of the reusable face mask using standard procedures, thereby rendering it perfectly safe for reuse. The rim 101 of the reusable face mask can make an air-tight seal with the face of the wearer.
Hence, the need for a cost-efficient reusable mask, with all the features provided by high-quality disposable masks is identified.

OBJECT OF THE INVENTION:
With reference to the above background explanation, the present invention of a solid state surface composite material for brake liner application produced through friction stir processing has following objectives to solve the limitations of the conventional surface properties.
The principal objective of the invention is that the face mask made up of flexible airtight material with in-built exhalation valve in the main body that can pre-deployed or could be deployed by applying incision on a designated location.
Another objective of the present invention is that face mask made up of transparent material so that the expressions of the user are visible through the mask.
Another objective of the present invention is that the capability to decontaminate the mask using standard procedures, ability to change the filtering element, and the mechanical design of filtering element itself.
Another objective of the present invention is that capability of mask making an airtight seal with the face of the user.

SUMMARY OF THE INVENTION:
A reusable facemask according to the present invention consisting of a main body, one or more cavities to mount or insert a replaceable filtering element with perforations to allow air to pass through the filter, one or more exhalation valve(s) being integrated within the main body that may be pre-manufactured as a flap or is to be deployed by applying incision on a designated location, a filter cartridge or replaceable filtering element designed to provide filtering action, mechanical stability and sealing effect to fit into the designated cavity, one or more exhalation valves being arranged on a case-to-case basis, a flexible rim is provided on the mask to create an air tight seal with the face of a user, a perforated retainer plate is provided within the main body of the mask to insert or secure the filter into the cavity and a razor-thin slit is cut through the body to the other wall of the mask.
Further, the face mask is made up of transparent and flexible airtight material and that is to be sterilized and reused. The mask provides an airtight sealing on the face. The mask contains perforations or a window for passing off air arrangements through the filter element. The mask provides the airtight seal between the flexible rim and the face of the user. The flexible rim of the mask ensures that the air ingress and egress takes place through the filter and the exhalation valve. The filter is in the form of a block or pad that fits in the filter cavity. The filter being encapsulated or attached in a perforated retainer box or frame and then that is to be inserted into the cavity. The valve is in closed position during the natural resting position during exhalation and the volume inside the mask develops higher air pressure during the inhalation thereby forcing open the orifice of the valve to allow the inside air to escape. The filter being first inserted and then secured using a perforated retainer plate or along with the retainer plate that is to be made a subassembly to be inserted into the cavity.

BRIEF DESCRIPTION OF THE DRAWINGS:
Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
Figure 1 is a structural view of a reusable face mask, according to the present invention.
Figure 2 illustrates a perspective view from the back side of a reusable face mask, according to the present invention.
Figure 3 illustrates various filter cartridge options along with a cross sectional view of a reusable face mask fitted with one of the options inside, according to the present invention.
Figure 4 illustrates a cross sectional view of the exhalation valve built in the main body of the reusable face mask, according to the present invention.
Figure 5 illustrates the principle of mechanized deployment and operation of the exhalation valve built in the reusable face mask, according to the present invention.
Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.

DETAILED DESCRIPTION OF THE INVENTION:
The nature of the invention and the manner in which it works is clearly described in the complete specification. The invention has various embodiments and they are clearly described in the following pages of the complete specification. Before explaining the present invention, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show illustrations in accordance with example embodiments. These example embodiments are described in enough detail to enable those skilled in the art to practice the present subject matter. However, it will be apparent to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. The embodiments can be combined, other embodiments can be utilized or structural and logical changes can be made without departing from the scope of what is claimed. The following detailed description is, therefore, not to be taken as a limiting sense, and the scope is defined by the appended claims and their equivalents.

Referring to the Figure 1 that illustrates the structural view of a reusable face mask, according to the present invention.

Particularly, Figure 1 illustrates different parts of the reusable face mask.
[REFERENCE NUMERALS]
101. Rim
102. Perforations to allow movement of air or gas
In one or more embodiments, a reusable face mask made with transparent and flexible airtight material equipped with a cavity (201) to hold a replaceable filter element, perforations (102) to let the air or gas through and in-built exhalation valve or valves (202). The flexible rim of the mask (101) creates an air-tight seal with the face of a user, ensuring that the air ingress and egress happens only through the filter and the exhalation valve or valves (202). The flexible material of the mask enables it to be sterilized a large number of times for reuse.
Further, the filter element can be made in different specifications as per different filtration needs for various applications. The filter element fits inside the cavity (302) in a secure manner. The filter is in the form of a block or pad (303) that fits in the filter cavity (302). The filter (305) can first be inserted and then secured using a perforated retainer plate (304), or the filter (305) along with the retainer plate (304) that makes a subassembly to be inserted into the cavity (302). The filter (307) is first encapsulated in a perforated retainer box (306), then that may be inserted into the cavity (302). This configurations are not limited to this and there may also be more configurations for serving the same basic purpose of filtering, providing it mechanical stability and sealing effect. The retainer plate in the end product may look different from the illustrations, but provides the fundamental purpose of giving rigidity to the filter material.
The exhalation valves (202,401) consists of a cavity (402) built into the body of the mask. During the initial manufacturing process, the valve orifice is not cut all the way through the body of the mask, but some material is left to keep it closed permanently. The exhalation valves (202,401) deployed as shown in (501) of Figure 5, by making an incision in the body of the mask using a blade. Once deployed, the valve cross section looks like (502) of Figure 5, where a razor-thin slit is cut through the body to the other wall of the mask. During inhalation, since the natural resting position of the valve is in closed position, and also since there is low air pressure inside the volume inside the mask, the valve slit remains closed as illustrated in(503) of Figure 5. During exhalation, the volume inside the mask develops higher air pressure, thereby forcing open the orifice of the valve as illustrated in(504) and allows the inside air to escape. This deployment, i.e. cutting open the slit of the valve or valves through the sharp blade can be done as per prescription provided by the doctor, and/or the instructions provided by the manufacturer of the mask. In another embodiment, the valve can be manufactured or developed as a flap covering an orifice on the body of the mask. It essentially serves the same purpose as described above. Typically, an infected patient must not release unfiltered air through the exhalation valve into the atmosphere. In this case, the patient should not deploy the exhalation valve on the face mask being used by them. On the other hand, if the mask is being used for self-protection, and the user is not a patient, they are recommended to deploy the exhalation valve for improved comfort while exhaling.
In one or more embodiments, a flexible rim is provided on the mask to create an air tight seal with the face of a user. A perforated retainer plate is provided within the main body of the mask to insert or secure the filter into the cavity and a razor-thin slit is cut through the body to the other wall of the mask. The mask contains perforations or a window for passing off air arrangements through the filter element. The mask provides the airtight seal between the flexible rim and the face of the user. The flexible rim of the mask ensures that the air ingress and egress takes place through the filter and the exhalation valve. The filter is in the form of a block or pad that fits in the filter cavity. The filter being encapsulated in a perforated retainer box and then that is to be inserted into the cavity. The valve is in closed position during the natural resting position during exhalation and the volume inside the mask develops higher air pressure during the inhalation thereby forcing open the orifice of the valve to allow the inside air to escape. The filter being first inserted and then secured using a perforated retainer plate or along with the retainer plate that is to be made a subassembly to be inserted into the cavity.

Figure 2 illustrates a perspective view from the back side of a reusable face mask, according to the present invention.
[REFERENCE NUMERALS]
201. Cavity for filter element
202. Exhalation valve
Particularly, Figure 2 illustrates the inside perspective view in which the cavity for filter element and the exhalation valve arrangement are shown.

Figure 3 illustrates various filter cartridge options along with a cross sectional view of a reusable face mask fitted with one of the options inside, according to the present invention.
[REFERENCE NUMERALS]
301. Body of the mask
302. Cavity for filter element
303. Filter pad or block
304. Perforated retainer plate
305. Filter pad or block
306. Perforated retainer box
307. Filter pad or block
Particularly, Figure 3 illustrates filter cartridge with protective cover in which cavity for filter element (302), the filter pad or block (303, 305, and 307), the perforated retainer plate (304) and perforated retainer box (306) arrangements within the body of the mask (301) are shown.

Figure 4 illustrates a cross sectional view of the exhalation valve built in the main body of the reusable face mask, according to the present invention.
[REFERENCE NUMERALS]
401. Exhalation valve(s)
402. International cross section of exhalation valve(s)
Particularly, Figure 4 illustrates the exhalation valve or valves arrangement outside of mask and inside of mask.

Figure 5 illustrates the principle of mechanized deployment and operation of the exhalation valve built in the reusable face mask, according to the present invention.
[REFERENCE NUMERALS]
501. To deploy create opening with a sharp blade
502. After incision is made
503. During inhalation valve is closed as atmospheric pressure is higher
504. During inhalation valve opens as atmospheric pressure is lower than inside
Particularly, Figure 5 illustrates the exhalation valve or valves closing and opening arrangements during the higher and lower atmospheric pressure.

Additionally, while the constructional and operational process described above and illustrated in the drawings is shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some constructional and operational steps may be added, some constructional steps may be omitted, the order of the constructional steps may be re-arranged, and/or some constructional steps may be performed simultaneously.

Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given.

CLAIMS

WE CLAIM:

1. A reusable face mask, comprising:
a main body;
a cavity to mount or insert a replaceable filtering element with perforations to allow air to pass through the filter;
an exhalation valve being integrated within the main body that is either pre-developed as a flap covering an orifice in the mask or to be deployed by applying incision on a designated location;
a filter cartridge with protective cover or replaceable filtering element designed to provide filtering action, mechanical stability and sealing effect to fit into the designated cavity;
a flexible rim is provided on the mask to create an air tight seal with the face of a user; and
a perforated retainer plate is provided within the main body of the mask to insert or secure the filter into the cavity.

2. The reusable face mask as claimed in claim 1, wherein the face mask is made up of transparent and flexible airtight material and that is to be sterilized and reused.

3. The reusable face mask as claimed in claim 1, wherein the mask provides an airtight sealing on the face.

4. The reusable face mask as claimed in claim 1, wherein the mask contains perforations or a window for passing off air arrangements through the filter element.

5. The reusable face mask as claimed in claim 1, wherein the mask provides the airtight seal between the flexible rim and the face of the user.
6. The reusable face mask as claimed in claim 1, wherein the flexible rim of the mask ensures that the air ingress and egress takes place through the filter and the exhalation valve.

7. The reusable face mask as claimed in claim 1, wherein the filter is in the form of a block or pad that fits in the filter cavity.

8. The reusable face mask as claimed in claim 1, wherein the filter being encapsulated or attached in a perforated retainer box or a frame and that is to be inserted into the cavity.

9. The reusable face mask as claimed in claim 1, wherein the valve is in closed position during the natural resting position during exhalation and the volume inside the mask develops higher air pressure during the inhalation thereby forcing open the orifice of the valve to allow the inside air to escape.

10. The reusable face mask as claimed in claim 1, wherein the filter being first inserted and then secured using a perforated retainer plate or along with the retainer plate that is to be made a subassembly to be inserted into the cavity.