Flat-Fold Respirator Flanges for Cup-Shaped Fit Stability
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Solution Overview
Problem
Flat-fold respirators struggle to maintain their cup-shaped configuration during use, leading to difficulties in achieving a snug fit and proper positioning on the wearer's face.
Innovation Solution
Incorporation of first and second flanges on opposing sides of the mask body that project laterally and frontally, providing structural integrity, ease of adjustment, and improved donning and doffing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flat-fold respirators are designed to be folded flat for storage and shipping, then they are convenient for storage and transportation, but they have difficulty maintaining their cup-shaped configuration during use
Solution Approach 1:
The mask body is divided into multiple panels that can be folded relative to each other, allowing the mask to be collapsed into a flat configuration for storage while maintaining the ability to form a cup-shaped configuration during use. The segmentation allows independent movement of mask panels while preserving overall structural integrity.
Solution Approach 2:
Flanges are added to specific locations on the mask body (front and side surfaces) rather than uniformly throughout, creating asymmetric structural reinforcement that maintains the cup-shaped configuration during use while allowing flat folding for storage. The strategic placement of flanges provides structural support where needed without preventing folding.
2Ease of manufacture
If flat-fold respirators are designed without permanent cup-shaped structure, then they can be folded flat, but they require additional components like weld lines, seams, folds, and stiffening members to maintain configuration
Solution Approach 1:
The flanges are integrated directly into the mask body structure rather than being separate attachable components. This merging of the flange structure with the mask body reduces the number of separate parts and assembly steps while providing the necessary structural reinforcement to maintain cup-shaped configuration.
Solution Approach 2:
The flanges serve multiple functions simultaneously: they provide structural reinforcement to maintain cup-shaped configuration, create grip surfaces for donning and doffing, and leverage harness strap tension to pull the mask body downward for proper positioning. This multi-functionality reduces the need for separate components for each function.
3Ease of operation
If flat-fold respirators lack structural reinforcement, then they are simpler to manufacture, but they cannot achieve snug fit or proper positioning on the wearer's face
Solution Approach 1:
The flanges are pre-formed as integral parts of the mask body structure, providing ready-made grip surfaces and structural reinforcement before the mask is donned. This preliminary preparation eliminates the need for additional assembly steps or adjustments during donning, as the structural elements are already in place to facilitate proper positioning and snug fit.
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 flanges maintain the mask's cup-shaped configuration, facilitate easy adjustment and positioning, and enhance the snug fit, making it easier to use and store.
Implementation Method 1
The flanges also act as a lever arm in response to a force from the tension generated by the harness strap
Implementation Method 2
a force from the tension generated by the harness strap
Data Source
AI summary
A flat-fold, filtering, face-piece respirator that has a harness, a mask body, and first and second flanges. The mask body is capable of being folded flat for storage and can be opened into a cup-shaped configuration for use. The mask body has a filtering structure and has the first and second flanges disposed on first and second mask body sides. The first and second flanges project both laterally x and frontally y from the mask body. The provision of the flanges on each side of the respirator is beneficial to ease of mask donning, doffing, and adjustment, and to face fit and maintaining the open shape or configuration of the mask body.