Thermally Deformable Face Seal for Respirators
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Solution Overview
Problem
Conventional respirators face challenges in achieving a comfortable, one-size-fits-all facial fit due to variations in face shapes and sizes, leading to inconsistent seals and reduced durability over time.
Innovation Solution
A respirator design featuring a face seal member with a phase change material component that adapts to facial contours, combined with a non-phase change material base component, providing enhanced shape retention and universal adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional injection molded rubber edge bead seals are used, then the seal can be attached to the mask body, but the seal is weak and susceptible to detachment after extensive use
Solution Approach 1:
The patent combines a thermoplastic elastomer base material with a thermally deformable seal material to create a composite facepiece structure. The thermoplastic elastomer provides structural strength and durability, while the thermally deformable material conform to the user's face for a secure seal. This composite approach resolves the contradiction by assigning different functional requirements to different materials within the same structure.
Solution Approach 2:
The patent utilizes thermal parameter changes to transform the physical state of the seal material. By heating the thermally deformable seal material above its glass transition temperature, the material becomes soft and moldable, allowing it to conform to the user's face. Upon cooling, the material solidifies and maintains the customized shape, providing a secure and durable seal that cannot detach.
2Reliability
If tight fit is achieved through adjustable straps and elastic bands, then the respirator can be held in place, but the tight fit makes the respirator uncomfortable and does not maintain consistent seal during facial movement
Solution Approach 1:
The patent incorporates a dynamic element through the thermally deformable seal material that can adapt its shape in response to thermal energy from the wearer's face. This dynamic adaptation allows the seal to maintain consistency during facial movements while distributing pressure evenly, thereby improving both seal reliability and wearer comfort compared to static tight-fitting designs.
Solution Approach 2:
The thermally deformable seal material performs self-adjustment by automatically conforming to the wearer's unique facial contours through heat transfer from the face itself. This self-service capability eliminates the need for extensive manual adjustment of straps and bands, providing both consistent seal and comfort without requiring the wearer to continuously adjust the device.
3Adaptability or versatility
If conventional molded face seal elements are used, then the seal can be formed into a specifically defined shape, but the seal is not adaptable to varied shapes and sizes of varied users
Solution Approach 1:
The patent employs parameter changes through thermal energy to transform the seal material from a rigid, pre-defined shape into a soft, adaptable state. When heated above its glass transition temperature, the thermally deformable material loses its fixed shape and becomes capable of conforming to any facial contour. Upon cooling, it solidifies into a precise custom shape matched to the wearer's face, thus achieving both adaptability and manufacturing precision.
Solution Approach 2:
The patent applies preliminary action by pre-forming the thermally deformable seal material into a generic shape that can subsequently be customized. The material is initially manufactured with a basic structure, then softened through thermal energy during use to allow the wearer's face to mold it into a precise custom configuration. This preliminary preparation enables both mass production efficiency and individual customization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a secure, leak-free seal for various users by using a phase change material that deforms to conform to facial shapes, maintaining shape retention and improving long-term durability.
Implementation Method 1
configured to provide cooling to a wearer by absorbing heat from a facial surface of the wearer
Implementation Method 2
the seal component comprises a phase change material and wherein the base component comprises a non-phase change material
Data Source
AI summary
Thermally deformable face seals and respirators including such face seals. The thermally deformable face seal structures comprise composite phase change materials that mold to the face of a user to provide a personalized but one-size-fits-all facial fit having excellent shape retention after use and long term durability. The phase change material is applied onto a base component to cover all or substantially all of the surface area of the base component and adapts to the face of the user to provide a secure, leak-free seal.