Method of Manufacturing an Anesthesia Face Mask

A method of manufacturing a mask, the method comprising:

• providing a shell having an inlet formed on a body of the shell and a flange formed around a lower end of the body, the flange forming a surface on a bottom thereof;
• providing a first film substrate having a first thickness;
• providing a second film substrate having a second thickness that is less than a thickness of the first film substrate;
• aligning the first film substrate with the second film substrate;
• bonding the first film substrate to the second film substrate around an outer edge and around an inner edge, the inner edge shaped to fit around a nose and mouth of a patient;
• cutting the first film substrate and the second film substrate around the outer edge and the inner edge of the first film substrate and the second film substrate such that a cutout is formed within the inner edge of the first film substrate and the second film substrate;
• wherein the bonded and cut first film substrate and second film substrate form a first sheet that is joined to a second sheet;
• and
• joining the shell to the first sheet at the surface formed on the bottom of the flange.

A method of manufacturing a mask, the method comprising:

• providing a shell having an inlet formed on a body of the shell and a flange formed around a lower end of the body, the flange forming a surface on a bottom thereof;
• providing a first film substrate formed of blow molded TPU film having a first thickness;
• providing a second film substrate formed of blow molded TPU film having a second thickness that is less than a thickness of the first film substrate;
• aligning the first film substrate with the second film substrate;
• bonding the first film substrate to the second film substrate around an outer edge and around an inner edge, the inner edge shaped to fit around a nose and mouth of a patient;
• cutting the first film substrate and the second film substrate around the outer edge and the inner edge of the first film substrate and the second film substrate such that a cutout is formed within the inner edge of the first film substrate and the second film substrate;
• wherein the bonded and cut first film substrate and second film substrate form a first sheet that is joined to a second sheet;
• and
• joining the shell to the first sheet at the surface formed on the bottom of the flange.