Respiratory Mask Upper Part with Variable Filler for Facial Adaptation
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Solution Overview
Problem
Respiratory masks face challenges in providing optimal wearing comfort and adaptability to different facial shapes and sizes, leading to pressure issues and increased production costs due to the need for multiple mask sizes and individualized parts.
Innovation Solution
The upper part of the mask features a hollow space filled with a filler material of varying elasticity, allowing for precise adaptation of wall thickness and rigidity, enabling better pressure distribution and reduced need for multiple sizes, achieved through injection or application of materials like silicone gel, foam, or saline solution, with optional protective layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mask upper part is made with uniform wall thickness, then the manufacturing process is simple, but the adaptability to different facial shapes and pressure distribution is poor
Solution Approach 1:
The mask upper part incorporates a filler material within its wall structure that creates local variations in thickness and density. The filler is distributed non-uniformly, with higher concentration in areas requiring increased adaptability and pressure distribution (such as the nose bridge and cheek areas), while maintaining thinner walls in less critical regions. This local quality variation enables the mask to conform to different facial shapes without requiring multiple sizes.
2Adaptability or versatility
If multiple mask sizes and individually molded parts are produced to fit different patients, then the adaptability and comfort are improved, but the production costs and device complexity increase
Solution Approach 1:
The mask upper part is designed as a universal component that can fit various facial shapes and sizes through the integrated filler structure. The filler material's variable distribution pattern allows a single mask design to adapt to different patients without requiring individually molded parts or multiple size variants. This universality reduces device complexity while maintaining high adaptability.
Solution Approach 2:
The filler material properties (density, elasticity, distribution) are varied within the mask wall to create regions of different rigidity and compliance. By changing these parameters locally, the mask achieves adaptability to different facial contours using a single standardized component rather than multiple customized parts.
3Strength
If the filler material is distributed uniformly throughout the mask wall, then the structural integrity is maintained, but the pressure distribution on the face is not optimized
Solution Approach 1:
The filler material is distributed non-uniformly within the mask wall, with varying concentrations in different regions. Areas requiring higher pressure distribution (such as the nose bridge and cheeks) contain higher filler density for enhanced comfort, while less critical areas maintain lower filler content to preserve structural integrity and reduce overall weight.
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
This solution enhances adaptability and comfort by optimizing pressure distribution and reducing production costs, allowing for a smaller number of mask sizes and improved sealing properties across various facial contours.
Implementation Method 1
The thickness or depth of the filling material (15) varies in the course of the cross section of the upper mask part (3)... varying elasticity
Implementation Method 2
filler of a certain consistency and elasticity... gel materials already mentioned, such as polyurethane or silicone gel
Data Source
Figure 1~2
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AI summary
The invention relates to an upper mask part of a respiratory mask, which is produced from elastic material having varying wall thickness levels of the walls over the course of the cross-section thereof. The upper mask part is connected to a mask body by a mask connecting region on the side facing away from the patient face. The respiratory mask has inwardly formed, thin peripheral contact lips on the side facing the patient face. The respiratory mask is fastened to the head of the patient using aids and has an air-conducting hose connection. At least one region shaped from a filling material is introduced In or on the walls of the upper mask part. The method is used to produce the upper mask part according to the invention.