Face Mask Shape-Preserving Seal and Segmented Strap Design
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Solution Overview
Problem
Current face mask designs often have gaps between the mask and the wearer's face, particularly around the nose, cheeks, and chin, leading to reduced efficacy in filtering airborne particles and causing discomfort due to excessive compressive force.
Innovation Solution
A face mask with a flexible filter body and a shape-preserving sealing strip that extends across the nose, cheeks, and chin areas, along with ear straps or a head strap, to securely fit the mask to the face, minimizing gaps and preventing airborne particulate matter entry or exit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic ear-loop straps are used to hold the mask against the face, then the mask can be secured to the wearer's face, but excessive compressive force is applied causing discomfort, skin irritation, and pain
Solution Approach 1:
The head strap is divided into multiple segments: a crown portion, two temple portions extending from the crown, and two ear-loop portions extending from the temple portions. This segmentation allows each portion to independently conform to different facial regions, distributing the securing force across multiple contact points rather than concentrating it on one area, thereby maintaining face seal reliability while reducing localized compressive force harm
Solution Approach 2:
The head strap transitions from a traditional planar ear-loop configuration to a three-dimensional spatial arrangement that extends across the crown and temples. This dimensional change enables the strap to utilize the head's natural contours in multiple directions, improving face seal through better geometric conformity while reducing the need for excessive force in any single direction
2Shape
If a short formable piece is pressed against soft skin to form the mask upper edge, then the mask can be shaped to the nose contours, but the piece becomes over-bent causing ends to lift and creating unexpected gaps in the infraorbital region
Solution Approach 1:
The nose piece is designed with dynamic properties that allow it to be flexible during application but maintain its formed shape afterward. The material and structural design enable the nose piece to adapt to the wearer's nose contours when shaped, then retain that configuration without over-bending, preventing end lift and maintaining reliable face seal in the infraorbital region
Solution Approach 2:
The nose piece parameters (length, flexibility, material properties) are optimized to achieve the right balance between formability and shape retention. By adjusting these parameters, the nose piece can be effectively shaped to nose contours without becoming too malleable or too springy, thereby maintaining face seal reliability while achieving proper nose contour fit
3Reliability
If rectangular mask design is used with taut straps in the corners, then the mask can be held against the face, but the straps create compressive force along the side edges bowing the mask material away from the face
Solution Approach 1:
The mask periphery is designed with curved portions that follow the natural contours of the face rather than straight rectangular edges. The side portions curve to accommodate the cheek contours, and the bottom portion curves to fit under the chin. This curvature eliminates the corner strap configuration that causes bowing, allowing the mask to maintain conformal contact with the face while achieving reliable face seal
Data Source
AI summary
Provided herein is a face mask that has a flexible filter body that is configured to fit over at least the mouth and the nose of a wearer. The face mask includes a shape-preserving strip extending along the periphery of the filter body. The shape-preserving strip is integral with the filter body and is configured to sufficiently seal the face mask against the wearer's face to minimize or prevent entry and/or exit of airborne particulate matter.