Moldable Surgical Mask with Filtered Valves for Sealing

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Solution Overview

Problem

Conventional surgical face masks are ineffective in sealing the human face due to their loose fit, allowing exhaled gases to bypass the filter and potentially exposing patients and wearers to contaminants, including surgical smoke, and fail to protect the wearer from hazards.

Innovation Solution

The development of moldable face masks with heat-activated thermoplastic members that conform to the individual's facial contours, incorporating filtered inhalation and exhalation valves to ensure a customized fit and effective filtration of both inhaled and exhaled air, along with a retention system for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional surgical face masks are used, then they are simple and easy to manufacture, but they have loose fit and allow exhaled gases to bypass the filter

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmask structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mask incorporates a moldable member that transitions from a rigid factory shape to a flexible molded state when exposed to body heat, allowing the mask to dynamically adapt to the wearer's unique facial contours. This dynamic transformation enables the mask to achieve a custom seal without requiring multiple sizes or complex adjustment mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The moldable member undergoes a parameter change in its physical state - transitioning from a rigid, pre-formed shape to a softened, moldable state through exposure to body heat (approximately 98.6°F or 37°C). This parameter change allows the material to conform to facial contours and then retain its molded shape, achieving reliable sealing.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If a non-filtered exhalation valve is incorporated, then exhaled gases can bypass the filter with less resistance providing greater comfort, but the exhaled products are not filtered

Engineering Contradiction:

Improvebreathing comfortVSAvoidunfiltered exhaled contaminants

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The valve assembly incorporates different functional zones: an exhalation path with lower flow resistance for comfort, and a separate inhalation path with filtration. The filter element is positioned to selectively filter inhalation air while allowing exhalation gases to escape with minimal resistance, achieving both comfort and protection.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The valve assembly acts as an intermediary mechanism that directs airflow through different paths - filtered air for inhalation and unfiltered (but lower resistance) path for exhalation. This intermediary structure resolves the contradiction by providing separate flow paths optimized for each direction.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a moldable member is added to customize mask fit, then sealing is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefacial sealVSAvoidmask production

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mask is segmented into distinct components: a main mask body and a separate moldable member. This segmentation allows the moldable member to be pre-formed in a standardized, easy-to-manufacture state and then activated by the user's body heat to achieve custom fit, combining manufacturing simplicity with sealing effectiveness.

Inventive Principle:

Principle #1Segmentation

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 moldable face masks provide a tight, customized fit that significantly reduces the flow of contaminants around the mask's perimeter, enhancing protection for both the wearer and patients by ensuring that a substantial portion of both inhaled and exhaled air passes through filtered valves, thereby improving safety and comfort while potentially reducing costs through reusability.

Implementation Method 1

at least one moldable member (e.g., without being limited thereto, a heat-activated thermoplastic member) coupled, for example, to所述 peripheral edge

Methodology Applied

Scientific EffectHeat activation: Heating

Implementation Method 2

a moldable member (e.g., heat-activated thermoplastic member) extends for at least a portion of所述 peripheral edge

Methodology Applied

Scientific EffectThermal softening: Melting

Implementation Method 3

said at least two valves each include a filter element

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS9320923B2Surgical face mask, including reusable masks, with filtered inhalation and exhalation valves

Publication Date: 2016.04.26 KOEHLER RICHARD H

AI summary

Face masks that can be used, for example, in medical and surgical procedures, including both completely or partially disposable and reusable masks, that can be custom fitted to the wearer, and which can include one or more filtering inhalation and exhalation valves and/or compartments allowing for separated filtering of inhalation and exhalation gases. Some embodiments include systems, methods and kits for reducing contaminants in an inhalation and exhalation flow stream.