Facemask Assemblies with Adjustable Strap and Foam Seal
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Solution Overview
Problem
Conventional facemasks fail to provide effective protection against airborne pathogens and particulates due to inadequate fit, low filtration efficiency, and discomfort, as they often lack a proper nasal seal, restrict the use of protective eyewear, and do not provide sufficient upward lift for a complete seal around the chin area.
Innovation Solution
A user-adjustable facemask with a dual polymer strap that combines ultra-high strength thermoplastic fibers with a low-temperature activated thermoplastic matrix, a snap-together frame for expanded breathable surface area, and a customizable seal system that includes a closed-cell foam interior band for improved fit and comfort, allowing for adjustable positioning of the strap to center inward pressure on the face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional facemasks use fixed elastic straps or ties, then the mask can be secured to the wearer's face, but the fit is inadequate and fails to provide proper nasal seal and chin area seal
Solution Approach 1:
The facemask employs dynamic elastic straps that can be adjusted in length and tension to adapt to different face shapes and sizes. The straps include adjustable connectors allowing users to customize the fit, transforming a static mask design into a dynamic, adaptable system that maintains reliable seal across diverse wearers.
Solution Approach 2:
The invention changes the parameters of the strap system by introducing adjustable length, variable tension, and multiple attachment points. This allows the mask to be customized for different face geometries, improving seal effectiveness while maintaining ease of adjustment for different users.
2Reliability
If conventional facemasks use tight elastic straps to seal against the face, then the mask secures to the wearer, but the straps pull the mask away from the upper nose seal area preventing complete seal
Solution Approach 1:
The strap system is segmented into multiple independent straps with separate adjustment mechanisms rather than a single tight strap. This segmentation allows different regions of the mask (nose area, cheeks, chin) to be secured independently, preventing the pulling effect that disrupts the nose seal while maintaining overall facial seal integrity.
Solution Approach 2:
Different portions of the mask are secured with locally optimized strap configurations. The upper portion near the nose uses lighter tension to preserve seal integrity, while lower portions use stronger securing. This local differentiation of strap tension and configuration resolves the conflict between overall seal reliability and local mask positioning.
3Adaptability or versatility
If conventional facemasks lack adjustable strap systems, then the structure is simple, but the mask cannot conform to different face shapes and sizes
Solution Approach 1:
The adjustable strap system serves multiple functions: it secures the mask to various face shapes, allows user customization, and maintains seal integrity across different wearers. This multi-functionality achieves high adaptability without proportionally increasing complexity, as the same adjustable mechanism serves multiple protective and fitting purposes.
Solution Approach 2:
The mask includes self-adjustment features where users can independently modify strap length and tension to fit their own face geometry. This self-service capability increases adaptability across diverse users without requiring complex adjustment mechanisms or professional fitting, thereby limiting the increase in device complexity.
4Reliability
If conventional facemasks use aluminum strips for nasal seal, then the mask structure is simple, but the seal is inadequate and restricts use of protective eyewear and glasses
Solution Approach 1:
The nasal seal uses a flexible foam strip instead of rigid aluminum. This flexible material can conform to different nose shapes and bridge heights, providing reliable seal while accommodating protective eyewear and glasses that rest on the nose. The flexibility allows the seal to adapt around eyewear contours rather than blocking them.
Solution Approach 2:
The nasal seal combines foam material with fabric layers to create a composite structure that provides both sealing effectiveness and compatibility with eyewear. The foam core provides the sealing function while the fabric outer layer reduces pressure points and allows eyewear to pass over comfortably, achieving both reliable seal and eyewear compatibility.
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 facemask provides a snug and comfortable fit, enhancing protection for the wearer and others by ensuring a better seal around the nose, cheeks, and chin, while allowing for easy cleaning and reuse, and incorporating a three-layer filter with enhanced filtration efficiency.
Implementation Method 1
a breathable three-layer filter material secured between the front clip and the back frame
Implementation Method 2
A facemask also includes a closed-cell foam interior band that provides a seal against a wearer's face
Data Source
AI summary
A facemask assembly including a framework and front clip and method of manufacturing the same where a filter material is inwardly folded over a back frame creating an expanded breathable filter surface area; and, a front clip with slot construct adapted for insertion of one or more of straps, cords, tubing and o-rings has a cell construct at the top of the post forming a quadrilateral cell from which the surrounding cell construct has one or more perpendicular members extending to one or more clips adapted to fit over a back frame. The filter material is cut and a facial sealing strip with conformal straps are bonded to the rim of the facemask.