Disposable Mask Nose Bridge Ultrasonic Welding
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Solution Overview
Problem
Existing disposable masks with metal nose bridges are costly to manufacture due to the high expense of metals like aluminum, and they often cause irritation to the user's skin, while also posing challenges in packaging and fitting.
Innovation Solution
A disposable mask design featuring a metal strip enclosed in plastic, ultrasonically welded to a non-woven fabric nose bridge, which can be pre-bent for comfort and ease of use, and manufactured using cost-effective methods such as extruding or laminating plastic over the metal strip, allowing for reduced metal usage and improved fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal strip is used for the nose bridge, then the structural integrity and fit are improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces expensive metal strips with a disposable plastic nose bridge that provides sufficient structural integrity for single-use masks. The plastic material (polypropylene or similar) is cost-effective and eliminates the need for costly metal components while maintaining adequate support for mask fitting.
Solution Approach 2:
The nose bridge is constructed as a composite structure combining plastic material with embedded wire or strip. This composite design provides the necessary rigidity and shape retention similar to metal, while using cheaper plastic as the primary material. The wire embedding within plastic creates a cost-effective alternative to solid metal construction.
2Ease of operation
If a metal nose bridge is used, then the fit and support are improved, but skin irritation occurs
Solution Approach 1:
The disposable plastic nose bridge eliminates skin irritation caused by metal by using non-metallic material that does not conduct temperature or cause allergic reactions. The plastic material is gentler on skin while still providing adequate support for mask fitting during the single use period.
Solution Approach 2:
The plastic nose bridge is designed with appropriate flexibility and thickness to conform to the user's nose shape while distributing pressure evenly. The plastic material provides a smooth, non-irritating surface contact compared to metal, while maintaining sufficient rigidity for structural support.
3Strength
If traditional manufacturing methods are used for metal nose bridges, then the structural integrity is maintained, but packaging becomes difficult
Solution Approach 1:
The disposable plastic nose bridge can be manufactured in pre-formed shapes and integrated directly into the mask during assembly. This eliminates the need for separate metal component handling and packaging, simplifying the overall packaging process while maintaining structural integrity through molded plastic construction.
Solution Approach 2:
The nose bridge is integrated as part of the mask assembly process rather than being a separate metal component requiring individual packaging. The plastic nose bridge is positioned and secured during mask manufacturing, combining multiple functions into a single integrated structure that simplifies packaging and handling.
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 manufacturing costs, enhances user comfort by distributing pressure evenly, and simplifies packaging and fitting, while maintaining the structural integrity of the nose bridge.
Implementation Method 1
ultrasonically welding the nose bridge to the piece of non-woven fabric
Data Source
Figure 1A~1B
Figure 2A~2D
Figure 2E~2I
AI summary
A disposable mask (100) comprising a fabric piece (102) and a nose bridge (104) comprising a metal strip (144) enclosed in plastic (142), wherein the nose bridge (104) is welded to the fabric piece (102).