Recycled Plastic Respirator Mask Filter Design
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Solution Overview
Problem
The increasing demand for respirator masks results in significant plastic waste, as they are typically made from virgin plastic materials and are intended for single use, posing an ecological concern.
Innovation Solution
A respirator mask designed with a filter material composed of recycled plastic non-woven fabrics and a securing band made from recycled materials, reducing the use of virgin plastic and promoting a more environmentally friendly production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If respirator masks are made from virgin plastic materials for single use, then filtering and protection properties are ensured, but plastic waste increases significantly
Solution Approach 1:
The patent changes the material parameter from virgin plastic to recycled plastic material, transforming the respirator mask from a single-use disposable product to a reusable product. This parameter change maintains the necessary filtering and protection properties while significantly reducing plastic waste generation.
Solution Approach 2:
The patent inverts the traditional disposable concept by creating a durable reusable mask from recycled materials, eliminating the need for frequent disposal. The mask can be cleaned and reused multiple times, directly addressing the plastic waste problem while maintaining protection effectiveness.
2Loss of substance
If recycled plastic materials are used in respirator masks, then ecological impact is reduced, but filtering performance may be compromised
Solution Approach 1:
The patent specifies that the recycled plastic material must meet certain performance parameters to ensure adequate filtering capability. By carefully selecting and processing recycled materials with appropriate properties, the mask maintains effective filtration while reducing ecological impact.
Solution Approach 2:
The patent may combine recycled plastic materials with other materials or use multi-layer constructions to achieve the necessary filtering performance. This composite approach allows the use of recycled content while ensuring the mask meets protection requirements.
3Ease of manufacture
If respirator masks are designed for single use, then manufacturing and disposal processes are simplified, but environmental sustainability is compromised
Solution Approach 1:
The patent transforms the respirator mask from a single-use disposable object to a reusable object made from recycled materials. This design choice prioritizes environmental sustainability over manufacturing simplicity, requiring cleaning and maintenance protocols but eliminating continuous production and disposal cycles.
Solution Approach 2:
The patent recovers plastic materials from waste streams and reuses them in new mask production, creating a circular economy approach. This recovering process replaces the linear take-make-dispose model, reducing waste while maintaining manufacturing feasibility through established recycling infrastructure.
Data Source
AI summary
The invention provides a respirator mask comprising a filter material piece made of an air-permeable material and at least one securing band, wherein the air-permeable material comprises at least one layer of a non-woven fabric comprising or consisting of fibres formed from one or more recycled plastic materials, and wherein the at least one securing band is designed for securing the respirator mask to the head.