Multi-layer Face Mask with Angled Filter Layers
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Solution Overview
Problem
Existing multi-layer face masks do not effectively improve filtration efficiency due to the alignment of openings between layers, allowing pathogens to pass through.
Innovation Solution
The use of filter layers oriented at different angles, such as a 45-degree angle between layers, ensures that openings do not align perfectly, creating smaller and more irregular combined openings that effectively block pathogens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple filter layers are stacked to improve filtration, then the number of layers increases, but the openings between layers may align and allow pathogens to pass through
Solution Approach 1:
The patent applies asymmetry by rotating adjacent filter layers at different angles (e.g., 0°, 45°, 90°, 135°) relative to each other. This asymmetric angular arrangement prevents the openings of woven yarns in one layer from aligning with openings in adjacent layers, thereby blocking pathogen transmission paths that would exist if layers were stacked with identical orientations.
2Reliability
If filter layers are rotated at different angles to prevent opening alignment, then filtration efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent changes the angular parameter of filter layer orientation to specific discrete values (0°, 45°, 90°, 135°). These standardized angular parameters simplify manufacturing by providing clear, repeatable rotation specifications for each layer, reducing the need for high-precision continuous angle control while still achieving effective opening misalignment.
3Reliability
If more filter layers are added to ensure pathogen blocking, then filtration reliability improves, but the mask becomes less breathable
Solution Approach 1:
The patent segments the filtration function across multiple layers, with each layer contributing to pathogen blocking through its unique angular orientation. This segmentation allows the system to achieve high filtration reliability with fewer layers compared to a single thick layer, as each angled layer creates independent blocking paths that collectively enhance both protection and breathability.
Data Source
AI summary
A face mask has a first woven filter layer comprising a first yarn and a second woven filter layer comprising a second yarn. The second yarn is disposed at a non-right and non-parallel angle relative to the first yarn. The second woven filter layer is stitched to the first woven filter layer. A third woven filter layer with a third yarn can be added with the third yarn at a non-right and non-parallel angle relative to both the first yarn and second yarn.