Medical Mask Orientation Structure with Deformable Material
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Solution Overview
Problem
Existing medical masks for treating sleep disordered breathing and other respiratory issues often have inadequate fits, leading to discomfort and leakage due to poor alignment with the user's facial features.
Innovation Solution
A medical mask system that includes a body and an orientation structure with a deformable material capable of transitioning between states, allowing for custom orientation with an oral appliance to ensure a secure and comfortable fit, using a thermoplastic polymer and locking mechanism to maintain the orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a standard medical mask is used, then the device is simple and inexpensive, but the fit is inadequate causing discomfort and leakage
Solution Approach 1:
The mask incorporates a deformable material component that can dynamically adapt its shape. The deformable material is positioned to receive an oral appliance post and can deform to conform to the user's unique facial geometry, transitioning from a generic shape to a customized fit without requiring complex manufacturing processes.
Solution Approach 2:
The mask utilizes changes in the physical state of a deformable material (such as temperature-induced phase changes) to transition between a moldable state during application and a fixed fitted state during use. This allows the mask to be manufactured as a standard component and then customized in-situ through parameter changes rather than requiring complex custom manufacturing.
2Reliability
If the mask is customized to fit the user's face, then leakage is reduced, but the device becomes more complex
Solution Approach 1:
The mask is divided into distinct functional segments: a rigid mask body providing structural integrity and gas delivery, and a separate deformable material component providing customization and sealing. This segmentation allows each component to be optimized independently - the body for manufacturability and the deformable portion for adaptation - reducing overall complexity compared to fully custom molded masks.
Solution Approach 2:
The deformable material acts as an intermediary element between the standard mask body and the user's unique facial features. Rather than requiring the entire mask to be custom-made, this intermediate component adapts to the user's anatomy while maintaining connection to the standardized mask body, achieving reliable sealing without full customization complexity.
3Manufacturing precision
If a deformable material is used to customize the mask, then the fit improves, but the manufacturing process becomes more complex
Solution Approach 1:
The deformable material is pre-positioned on the mask body in a ready-to-deform state during manufacturing. This preliminary placement allows the material to be prepared in advance but remains inert until application, when it is activated (e.g., through temperature changes) to deform and conform to the user's face. This separates manufacturing from customization, maintaining ease of manufacture while enabling precise custom 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 system provides an improved fit, reduced leakage, and increased comfort by customizing the mask to the user's unique facial features, enhancing the effectiveness for treating sleep disordered breathing and other respiratory conditions.
Implementation Method 1
The orientation structure includes a deformable material which includes a second polymer capable of transitioning between deformable and non-deformable states
Data Source
AI summary
In one embodiment, a medical mask includes a body and an orientation structure. The body includes a first polymer, is configured to cover portions of a user's face comprising the user's mouth and at least portions of the user's nose comprising the nostrils, and is further configured to contact the user's face surrounding the covered portions of the user's face to substantially prevent gas from escaping between the body and the contacted portions of the user's face. The orientation structure is configured to receive an oral appliance post to establish and maintain a custom orientation between the medical mask and the oral appliance post and the orientation structure includes a deformable material which includes a second polymer capable of transitioning between deformable and non-deformable states.