Mask Ear Hooking Parts Segmentation Design
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Solution Overview
Problem
Conventional masks with sheet-like ear hooking parts face issues of material waste and hindered high-speed production due to the need for cutting away parts to form ear hooking holes.
Innovation Solution
A mask design featuring ear hooking parts with extension members and connecting members that allow for continuous formation without cutting, enabling high-speed production and reduced material waste, with the ear hooking parts being separable and easily attachable to the mask body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If ear hooking parts are formed by cutting away parts of sheet to provide ear hooking holes, then ear hooking holes are formed, but material is wasted
Solution Approach 1:
The ear hooking part is divided into multiple components: extension parts that extend along the peripheral edges and a connecting part that connects these extension parts. This segmentation allows the ear hooking hole to be formed without cutting away material from a continuous sheet, as the hole is created by the arrangement and bonding of discrete extension parts along the edges.
Solution Approach 2:
The extension parts are pre-formed and bonded to the mask body at specific locations before the final ear hooking hole is created. The connecting part is then bonded to the extension parts to complete the ear hooking structure. This preliminary action sequence eliminates the need for post-formation cutting operations.
2Productivity
If sheet continuous body is used with unnecessary parts cut away, then ear hooking parts are formed, but high-speed production is hindered
Solution Approach 1:
The ear hooking part is segmented into extension parts and connecting parts that can be independently formed and bonded. This segmentation enables the use of a die-cutter that can process the continuous body without requiring complex conveyance systems, as the segmented parts can be cut and bonded in a streamlined manner.
Solution Approach 2:
The mask body and ear hooking parts are formed from continuous sheets that are conveyed through the die-cutter in a continuous process. The extension parts are bonded to the mask body and the connecting parts are bonded to the extension parts in a continuous operation, eliminating interruptions and enabling high-speed production.
3Ease of manufacture
If ear hooking parts are bonded to mask body, then mask structure is complete, but bonding process complexity increases
Solution Approach 1:
The ear hooking part is segmented into extension parts and connecting parts with distinct bonding locations. The extension parts are bonded to the mask body at specific locations, and the connecting parts are bonded to the extension parts. This segmentation allows for simplified bonding processes as each segment has a defined bonding location and method.
Solution Approach 2:
The extension parts serve as intermediaries between the mask body and the connecting parts. These intermediaries are bonded to the mask body first, providing a stable foundation for bonding the connecting parts. This intermediary approach simplifies the overall bonding process by breaking down the complex assembly into simpler, staged operations.
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 solution reduces material waste and enables high-speed mask production by eliminating the need for cutting away parts to form ear hooking holes, while ensuring the mask is hygienic and easy to put on.
Implementation Method 1
The bonded part 131 is bonded to an end area 121 of the mask body 120 through bonding points 122 by fusing.
Data Source
AI summary
Provided are: a mask which can be manufactured with less waste of material and at a high speed; and a method for manufacturing same. A mask body has first and second peripheral edges extending in a first direction and third and fourth peripheral edges extending in a second direction intersecting with the first direction. A pair of ear hooking parts has (i) a pair of extension parts extending along the first and second peripheral edges of the mask body, with one end of each extension part bonded to a side edge part of the mask body; and (ii) a connecting part distinct from the pair of extension parts, the connecting part being bonded to the corresponding other ends of the pair of extension parts and extending in the second direction.