Pleated Respirator Openwork Support for Facial Conformity

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Solution Overview

Problem

Conventional molded filtering face piece respirators are rigid and non-resilient, limiting their ability to conform to facial movements and fit a wide range of facial sizes, while also restricting airflow and comfort.

Innovation Solution

A pleated filtering face piece respirator design featuring openwork pleated flexible plastic layers supporting pleated filter material, with additional layers for comfort and resilience, allowing for flexibility and increased airflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional molded filtering face piece respirators are made from flat layers of melt blown filter media, then structural rigidity is provided, but flexibility and ability to conform to facial movements are limited

Engineering Contradiction:

Improvestructural rigidityVSAvoidflexibility and facial conformity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The respirator is divided into multiple functional layers including support layers, filter media layers, and sealing layers, each with specific properties that collectively provide both rigidity and flexibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The respirator incorporates dynamic elements such as elastic materials and pleated structures that allow the mask to adapt its shape and conform to facial movements while maintaining structural integrity

Inventive Principle:

Principle #15Dynamics

2Productivity

If pleated filter media is used to increase surface area, then filtration performance and breathing ease are improved, but structural rigidity is reduced

Engineering Contradiction:

Improvefiltration performanceVSAvoidstructural rigidity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

Different regions of the respirator have different structural properties - the pleated filter media provides high surface area for filtration, while support layers in other regions provide necessary structural rigidity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The respirator uses composite construction combining pleated filter media with support layers of elastic and non-elastic materials, creating a structure that achieves both high filtration performance and structural stability

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the respirator is made rigid to maintain structure, then structural integrity is preserved, but ability to expand and contract with facial movements is restricted

Engineering Contradiction:

Improvestructural integrityVSAvoidfacial movement accommodation

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The respirator uses flexible elastic materials and thin film structures that can deform with facial movements while maintaining the overall structural integrity and functional performance

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of manufacture

If flat filter media is used, then manufacturing is simpler, but surface area and breathing ease are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfilter surface area

Core Design Contradiction:

Ease of manufactureVSArea of moving object

Solution Approach 1:

The filter media is pleated to create a three-dimensional structure that increases surface area while maintaining manufacturability through standard pleating processes

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 design provides improved facial contact and fit, enhanced filtration performance, and increased comfort by allowing the respirator to expand and contract with facial movements while maintaining structural integrity and airflow.

Implementation Method 1

The openwork pleated flexible plastic material may be formed from a plastic sheet that has a pattern of openings or may be formed from a sheet of woven material or may be formed from a sheet of mesh material

Methodology Applied

Scientific EffectPleating: Corrugation

Implementation Method 2

The resilient polymer netting or nettings serving as the carrier for the filter material is of sufficient resilience to return to its original three dimensional form when not under stress

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10834980B2Pleated filtering face piece respirator

Publication Date: 2020.11.17 MOLDEX METRIC INC

AI summary

A pleated molded filtering face piece respirator to be worn upon the face of a wearer and for providing filtering including at least one layer of moldable flexible plastic material formed from openwork flexible plastic material for providing a plurality of perforations for allowing for the free passage of air through the openwork plastic. A layer of moldable filter material for filtering impurities in the air, the one layer of flexible plastic material formed from openwork flexible plastic material and the layer of filter material for filtering impurities in the air lying one on top of the other to form a moldable multilayer of flexible plastic material and filter material. The moldable multilayer of flexible plastic material and filter material are pleated into pleated material and molded to form the pleated filtering face piece respirator to a desired configuration where the one layer of openwork flexible plastic material forms a support layer to carry the layer of filter material.