Customized Face Mask Contact Frame for Pressure Relief
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Solution Overview
Problem
Face masks worn for extended periods, especially by medical staff, cause discomfort due to pressure points leading to skin constriction, pain, and potential hematoma, as existing masks do not adequately accommodate individual facial anatomy.
Innovation Solution
A user-specific face mask is produced by recording facial data, creating a 3D model, and manufacturing a contact frame that adapts to the individual's facial structure, ensuring a comfortable fit and connection to a functional device with a filter and optional valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard face mask is worn for extended periods, then disease protection is maintained, but pressure points form causing skin constriction and pain
Solution Approach 1:
The contact frame is designed with varying thicknesses at different locations to match the user's facial anatomy. Thicker regions provide cushioning for bony areas while thinner regions conform to softer tissues, creating localized comfort zones that prevent pressure points while maintaining overall seal integrity for disease protection
Solution Approach 2:
The contact frame utilizes thermoplastic material that changes its physical parameters in response to body heat. The material transitions from a rigid molding state during manufacturing to a flexible, conforming state when warmed by the user's face, allowing the frame to adapt to individual facial shapes and reduce pressure points while maintaining protective function
2Ease of operation
If a customized contact frame is manufactured for each user, then wearing comfort is improved, but manufacturing complexity increases
Solution Approach 1:
The system creates a digital 3D copy of the user's face through optical scanning or photogrammetry. This virtual model serves as the basis for generating the customized contact frame, eliminating the need for physical mold-making and complex manual fabrication processes while maintaining precise anatomical accuracy for optimal comfort
Solution Approach 2:
The contact frame is manufactured as a single integrated component using additive manufacturing or injection molding, rather than assembling multiple separate parts. This homogeneous construction simplifies the manufacturing process and reduces assembly complexity while maintaining the customized geometry required for comfortable fit
3Ease of operation
If the contact frame is made thicker to provide cushioning, then pressure points are reduced, but the fit and seal effectiveness deteriorate
Solution Approach 1:
The contact frame employs non-uniform thickness distribution where thicker sections (3-5mm) are positioned over bony facial areas for cushioning, while thinner sections (1-2mm) conform to softer tissues and critical seal areas. This localized variation maintains both pressure distribution and seal effectiveness across different facial regions
Solution Approach 2:
The thermoplastic material provides dynamic adaptability, allowing the contact frame to change its effective thickness and conformity in response to the user's facial geometry and body temperature. The material flows and conforms to the face during use, optimizing both cushioning and seal contact without requiring uniformly thick construction
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 method provides high wearing comfort by creating a customized contact frame that fits the user's face, reducing pressure points and enhancing the fit of the mask, thereby improving usability and reducing discomfort.
Implementation Method 1
facial data of a user's facial area to be protected is recorded, in particular by means of an optical detection device
Implementation Method 2
The contact frame preferably comprises a soft material, for example an elastomer, in particular a thermoplastic, a silicone and/or a polyurethane foam
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing a user-specific face mask, in which, in particular optically, facial data of a facial area (14) to be protected of a user (10) are captured, a three-dimensional model of the facial area (14) is created, and a user-specific contact frame (20) is manufactured on the basis of the model, wherein the contact frame (20) is connected airtight to a functional device (24), wherein the functional device (24) comprises at least one filter (26) for filtering moisture particles from the air.