Athletic Face Mask with Intermediate Frame for Comfort
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Solution Overview
Problem
Conventional face masks are uncomfortable for long-term wear due to direct contact with the face, causing pressure, moisture buildup, and skin issues, and are often ineffective in high-impact settings or when improperly fitted, restricting airflow and causing fogging of glasses.
Innovation Solution
The PRODIGY™ mask features a novel face piece with a sturdy intermediate frame that stands off from the face, providing comfort and stability with a snug nose seal, adjustable straps, and a design that collapses on impact, along with a customizable outer layer for improved airflow and expression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional masks use elastic bands that wrap around the face and press fabric against the user's face, then the mask is secured in place, but it causes discomfort, pressure, moisture buildup, and skin issues during long-term wear
Solution Approach 1:
The patent introduces a headband as an intermediary component that replaces direct facial contact with indirect support. The headband wraps around the head to provide mask stability, while the mask body is positioned away from the face using spacers or a frame structure, eliminating direct pressure on the facial skin and preventing moisture buildup and skin issues during extended wear periods.
Solution Approach 2:
The mask is divided into separate functional components: a headband for securing the mask to the head, a mask body for filtration, and spacers or frame elements that create distance between the mask body and the facial skin. This segmentation allows each component to perform its specific function without causing the adverse effects of integrated conventional designs.
2Reliability
If conventional masks press filter material directly against the user's face, then protection from airborne particulates is provided, but it causes discomfort, moisture buildup, itchiness, and skin rashes
Solution Approach 1:
Spacers or frame structures act as intermediaries between the mask body and the user's face, maintaining a gap that prevents direct contact. This allows the filter material to remain effective for particulate protection while eliminating the harmful effects of direct facial contact, including skin irritation, moisture buildup, and itchiness.
Solution Approach 2:
The design transitions from a two-dimensional flat mask configuration to a three-dimensional structured mask with vertical spacing created by spacers or frames. This dimensional change positions the filter material away from the facial surface in the vertical dimension, maintaining filtration effectiveness while eliminating skin contact issues.
3Reliability
If conventional masks are improperly sized or donned, then they may be ineffective at protecting the wearer, but adjusting the fit increases pressure and discomfort
Solution Approach 1:
The headband serves as a mediator for fit adjustment, allowing the mask to be secured to the head without pressing the mask body against the face. This enables proper positioning for effective aerosol deflection while eliminating the pressure and discomfort associated with conventional tightening methods.
Solution Approach 2:
The mask design incorporates adjustable elements such as flexible headbands and adaptable frame structures that can dynamically conform to different head shapes and sizes. This allows the mask to achieve proper fit for effective protection without requiring excessive pressure that would cause discomfort.
4Reliability
If conventional masks use loops around the ears for securing, then the mask is held in place, but it causes discomfort during long periods of wear
Solution Approach 1:
The headband acts as an intermediary securing mechanism that replaces ear loops. It distributes the masking force around the entire head rather than concentrating it on the ears, providing reliable mask positioning while eliminating the discomfort and pressure points caused by ear loop contact during extended wear periods.
Data Source
AI summary
A face mask that may be constructed from a series of interchangeable pieces that will form a mask that does not rest against the user's face and may allow for increased breathability and sealing.