Multi-layered PPE Structure with 3D Spacers for Splash Resistance
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Solution Overview
Problem
Existing personal protective equipment (PPE) such as face masks and surgical gowns face challenges in achieving high splash resistance without increasing weight, cost, or discomfort, as traditional methods like adding layers or using high loft materials can lead to saturation and fluid transfer.
Innovation Solution
A multi-layered structure incorporating three-dimensional spacers made from a binder, ink, or adhesive with encapsulated phase change materials, which create channels to redirect fluid flow and enhance energy absorption, reducing the need for additional layers and improving comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thicker materials or additional layers are used to improve splash resistance, then splash resistance is improved, but weight increases and comfort deteriorates
Solution Approach 1:
The patent introduces three-dimensional spacers that create vertical spacing between layers, transforming a two-dimensional layered structure into a three-dimensional configuration. This dimensional change allows fluid to be redirected laterally through channels formed by the spacers, improving splash resistance without adding more material layers or increasing weight.
Solution Approach 2:
The patent segments the fluid flow path by introducing spacers that divide the space between layers into multiple channels. These channels redirect fluid laterally away from the wearer's face, segmenting the impact path and improving protection without requiring additional heavy layers.
2Reliability
If thicker materials or additional layers are used to improve splash resistance, then splash resistance is improved, but cost increases
Solution Approach 1:
By using three-dimensional spacers to create vertical spacing and lateral channels, the patent achieves improved splash resistance without requiring additional material layers. This dimensional approach reduces material consumption and manufacturing complexity compared to adding multiple thick layers or additional protective layers.
3Reliability
If thicker materials or additional layers are used to improve splash resistance, then splash resistance is improved, but porosity decreases and breathability deteriorates
Solution Approach 1:
The three-dimensional spacers create vertical spacing that maintains porosity between layers while forming lateral channels for fluid redirection. This dimensional configuration allows the structure to achieve splash resistance without compacting or reducing the porous nature of the material layers, thereby preserving breathability.
4Loss of energy
If high loft fibrous material is used to absorb splash energy, then energy absorption is improved, but the material saturates and fluid transfers to subsequent layers
Solution Approach 1:
The three-dimensional spacers act as intermediaries that create channels between the outer layer and inner layer. These channels redirect fluid laterally before it can penetrate through to subsequent layers, preventing saturation of energy-absorbing materials and maintaining the fluid barrier effectiveness of the entire structure.
Solution Approach 2:
By creating vertical spacing through three-dimensional spacers, the patent establishes lateral channels that redirect fluid flow horizontally rather than vertically. This dimensional redirection prevents fluid from saturating the high loft material and transferring to subsequent layers, maintaining reliability.
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 structure provides enhanced splash resistance while maintaining comfort and reducing material usage, allowing for lighter, breathable, and cost-effective PPE with improved filtration efficiency and thermal management.
Implementation Method 1
The plurality of three-dimensional spacers include an encapsulated functional additive contained within the binder, the ink, the adhesive, or the combination thereof, where the functional additive comprises a phase change material.
Data Source
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AI summary
A splash resistant multi-layered structure is provided. The structure includes a specific arrangement of layers of material and a plurality of three-dimensional spacers (302) that helps prevent penetration through the structure by a fluid that contacts an outer surface of the structure due to a state of forced separation that exists between two adjacent layers (300, 400, 802, 804, 806, 808) of the structure due to the presence of the plurality of three-dimensional spacers positioned between the layers. The plurality of three-dimensional spacers can be positioned on one of the adjacent layers (300, 802, 804, 806, 808) of the structure such that a distance (D) at least as large as the maximum height (S) of the plurality of three-dimensional spacers separates the two layers from each other and can be present on a layer of material in a continuous or discontinuous pattern or can be present on a layer of material in a random fashion. The presence of the three-dimensional spacers can reduce the basis weight or eliminate one or more layers of the structure, which, in turn, can reduce thermal resistance, lower the pressure drop across the layers of the structure, and reduce the overall weight of the structure to enhance breathability and comfort.