Mask Conversion Frame With Cushion Seal for Airflow Gap Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing personal protective equipment (PPE) masks, such as surgical masks and N95 respirators, often fail to provide an optimal seal with the wearer's face, leading to compromised filtration and increased airflow gaps, and they lack ergonomic comfort and reliable quality certification.
Innovation Solution
A facial covering assembly comprising an inner and outer frame with adjustable apertures and cushioning elements that create an airtight seal, combined with filtering sheets and user engagement features, to enhance mask fit and filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional surgical masks or N95 respirators are used, then basic filtration is provided, but mask fit and seal are compromised leading to airflow gaps
Solution Approach 1:
The mask is divided into multiple functional layers including an inner frame, outer frame, cushioning element, and filtering sheet. Each component serves a specific function: the frames provide structural support, the cushioning element creates the seal, and the filtering sheet performs filtration. This segmentation allows optimization of each component independently to achieve both reliable sealing and comfort.
Solution Approach 2:
Different regions of the mask have different properties tailored to their specific functions. The cushioning element has soft, compliant material properties for sealing against the face, while the frames have rigid structural properties for maintaining shape. The filtering sheet has porous properties for filtration. This local differentiation of material properties enables the mask to simultaneously achieve reliable seal and comfort.
2Reliability
If tighter sealing masks are used to improve filtration, then airflow gaps are reduced, but comfort and ergonomics deteriorate
Solution Approach 1:
The cushioning element is made from a flexible, compliant material that can conform to the contours of the user's face. This flexible seal interface creates an airtight seal without requiring excessive tightening forces, thereby maintaining filtration efficiency while preserving comfort and ergonomics during extended wear.
Solution Approach 2:
The mask employs composite construction combining rigid frame materials with flexible cushioning materials and porous filtering materials. This composite approach allows the rigid frames to maintain structural integrity for sealing, while the flexible cushioning layer adapts to facial contours, achieving both high filtration efficiency and ergonomic comfort.
3Reliability
If existing masks are used without conversion, then simplicity is maintained, but durability and filtration efficiency are limited
Solution Approach 1:
The mask components are nested within each other: the filtering sheet is positioned between the inner and outer frames, the cushioning element is attached to the inner frame and contacts the face, and various engagement features are integrated into the frame structure. This nested arrangement maximizes the functional density within a compact structure, achieving enhanced durability and filtration without excessive complexity.
Solution Approach 2:
The frame structure serves multiple functions simultaneously: it provides structural support, holds the filtering sheet, attaches the cushioning element, and incorporates engagement features for securing the mask. This multi-functionality reduces the need for separate components, maintaining structural simplicity while achieving enhanced durability and filtration efficiency.
Data Source
AI summary
A device may include an inner frame comprising at least one aperture to allow air flow through the inner frame. A device may include an outer frame configured to couple to the inner frame, the outer frame comprising at least one aperture to allow air flow through the outer frame. A device may include a cushioning element configured to couple to the inner frame, the cushioning element configured to establish a seal around at least a portion of a user's face. A device may include a shaper comprising one or more arms coupled to the inner frame and extending across the at least one aperture of the inner frame, the shaper comprising a midsection disposed at a central portion of the at least one aperture of the inner frame, wherein the midsection has greater width or height than the one or more arms.