Molded Thermoset Elastomeric Seal for Respirator Attachment

Solution Overview

Problem

Existing respirator designs require separate gaskets and mechanical seals for air-tight fastening, increasing complexity and cost, while also being prone to debris interposition and assembly variability.

Innovation Solution

A respirator attachment component with a molded thermoset elastomeric seal that is chemically bonded to the attachment component body, providing an integral sealing element that reduces assembly parts and variability, and enhances durability by preventing debris interposition, using thermosetting silicone materials that do not require surface priming for bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate gaskets and mechanical seals are used for air-tight fastening, then the seal reliability is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveseal reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the sealing function with the attachment component body by chemically bonding a thermoset elastomeric seal directly to the rigid attachment component. This integration eliminates the need for separate gaskets and mechanical seals, reducing device complexity while maintaining air-tight sealing reliability between the inhalation/exhalation components and the respirator structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite structure consisting of a rigid thermoplastic attachment component body chemically bonded to a flexible thermoset elastomeric seal. This composite material approach allows the sealing element to be integrally formed with the structural component, providing both mechanical strength and sealing functionality in a single unified part that reduces assembly complexity

Inventive Principle:

Principle #40Composite materials

2Reliability

If separate gaskets and mechanical seals are used for air-tight fastening, then the seal reliability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveseal reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the sealing function with the attachment component body by chemically bonding a thermoset elastomeric seal directly to the rigid attachment component. This integration eliminates the need for separate gaskets and mechanical seals, reducing device complexity while maintaining air-tight sealing reliability between the inhalation/exhalation components and the respirator structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealing element is chemically bonded to the attachment component body during the molding process itself, before final assembly. This preliminary bonding action ensures the seal is permanently attached and eliminates the need for separate assembly steps, reducing manufacturing complexity and cost while ensuring consistent seal quality

Inventive Principle:

Principle #10Preliminary action

3Reliability

If separate gaskets and mechanical seals are used for air-tight fastening, then the seal reliability is improved, but the assembly variability increases due to debris interposition

Engineering Contradiction:

Improveseal reliabilityVSAvoidassembly variability

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent combines the sealing function with the attachment component body by chemically bonding a thermoset elastomeric seal directly to the rigid attachment component. This integration eliminates the need for separate gaskets and mechanical seals, reducing device complexity while maintaining air-tight sealing reliability between the inhalation/exhalation components and the respirator structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealing element is chemically bonded to the attachment component body during the molding process itself, before final assembly. This preliminary bonding action ensures the seal is permanently attached and eliminates the need for separate assembly steps, reducing manufacturing complexity and cost while ensuring consistent seal quality

Inventive Principle:

Principle #10Preliminary action

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 achieves a robust, air-tight seal with increased durability and reduced complexity, as demonstrated by high average force to failure tests and effective air-tightness measurements, while eliminating the need for separate gaskets and mechanical seals.

Implementation Method 1

A respirator attachment component with a molded thermoset elastomeric seal that is chemically bonded to the attachment component body

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Data Source

PatentEP2185244B1Respirator attachment component with molded thermoset elastomeric seal

Publication Date: 2017.06.28 3M INNOVATIVE PROPERTIES CO

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AI summary

Respirator attachment components are described and include a polymeric rigid respirator attachment body portion having a first surface and a second surface and a silicone sealing element chemically bonded to the first or second surface.