Disposable Mask Assembly with Snap-Fit Filter Housing
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Solution Overview
Problem
Existing face mask assemblies for patients are complex, limit filter interchangeability, expose healthcare personnel to exhaled gases and medication mist, and require numerous parts for manufacture and assembly, failing to effectively minimize the release of patient exhaled gases and surplus medication into room air.
Innovation Solution
A face mask assembly with a simplified design featuring a snap-fitting mechanism between a filter housing and a cover with an exhalation vent, reducing the number of parts and enabling easy interchangeability of filters, while securing a filter between the filter housing and cover to minimize gas release into the atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex filter system with multiple moving parts is used, then disease transmission prevention is improved, but device complexity increases and filter interchangeability is limited
Solution Approach 1:
The mask assembly is divided into separate functional modules: a reusable mask body and replaceable filter cartridges. The filter cartridge includes a filter housing with a filter element and a cover with an exhalation vent, which can be independently replaced. This segmentation allows the complex filtering function to be isolated in a disposable cartridge while the mask body remains simple and reusable.
Solution Approach 2:
The filter cartridge is designed as a disposable component that is discarded after use, eliminating the need for cleaning, maintenance, or sterilization of the filter elements. This disposable approach reduces device complexity by removing moving parts and maintenance requirements while ensuring reliable disease transmission prevention through fresh filters for each patient.
2Reliability
If multiple filters are mounted on each side of the mask, then disease transmission prevention is improved, but device complexity increases
Solution Approach 1:
The inhalation filter and exhalation filter are combined into a single integrated filter cartridge assembly. The cartridge contains both filter elements positioned to handle inhalation and exhalation flows separately, merging multiple filtering functions into one replaceable unit that simplifies the overall mask structure while maintaining comprehensive disease transmission prevention.
3Device complexity
If an exhalation filter is not positioned between a flange portion and a cover with an exhalation vent, then device complexity is reduced, but exposure of harmful agents to others increases
Solution Approach 1:
The exhalation vent is extracted and positioned in the cover portion of the filter cartridge, separate from the filter element itself. This allows the exhalation flow to be directed through the filter element and then vented through a dedicated opening in the cover, ensuring that exhaled gases are filtered before release while maintaining a simple structure with no moving parts.
4Manufacturing precision
If numerous parts are used for manufacture and assembly, then manufacturing precision can be optimized, but ease of manufacture decreases
Solution Approach 1:
The filter housing and cover are designed to be molded as a single integrated component or easily assembled with minimal parts. The filter element is secured within the housing using simple retention features such as ribs, grooves, or adhesive, eliminating the need for complex fastening mechanisms. This merging approach maintains manufacturing precision for the filter-sealing interface while dramatically simplifying the overall manufacturing process.
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 effectively minimizes the release of patient exhaled gases and surplus medication, reducing exposure risks for healthcare personnel and simplifying assembly and manufacturing, while maintaining a breathable atmosphere for the patient.
Implementation Method 1
a snap-fitting mechanism between a filter housing and a cover with an exhalation vent
Implementation Method 2
securing a filter between the filter housing and cover to minimize gas release into the atmosphere
Implementation Method 3
having an exhalation vent to allow gases from the mask chamber to pass through the filter and escape from the passageway to the atmosphere
Data Source
AI summary
A face mask assembly and method of assembling a face mask is provided for a patient that includes a face piece sized to fit over the patient's nose and mouth. The face mask assembly forms a mask chamber between the face piece and the patient's nose and mouth. An inhalation adapter is coupled to the face piece to deliver medication to the chamber. A filter housing is coupled to the face piece and includes a flange section that defines a passageway to connect the mask chamber and the flange section. A filter is positioned in the filter housing. A cover is coupled to the flange section and has an exhalation opening or vent to allow gases from the mask chamber to pass through the filter and escape from the passageway to the atmosphere.