Sanitizing Face Mask with Antimicrobial Intermediate Layer

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Solution Overview

Problem

Existing face masks do not provide adequate protection against the transmission of pathogens in air respired through the nose and mouth, as they rely solely on mechanical filtering and do not effectively kill microbes present in exhaled air.

Innovation Solution

A sanitizing face mask with an intermediate layer saturated with a sanitizing liquid that kills pathogens in the air passing through the mask, providing both mechanical filtration and antimicrobial action.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mask uses only mechanical filtration layers, then it can maintain good breathability and low airflow resistance, but it cannot effectively kill pathogens in the air passing through it

Engineering Contradiction:

Improvepathogen killing effectivenessVSAvoidmask structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines mechanical filtration layers with a liquid-carrying layer containing antimicrobial agents. This composite structure integrates both physical filtration and chemical pathogen elimination functions within a single mask system, resolving the contradiction between mechanical filtration effectiveness and pathogen killing capability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The liquid-carrying layer acts as an intermediary between the mechanical filtration layers and the pathogens. It delivers antimicrobial agents directly to pathogens that pass through or are trapped by the mechanical filtration, enabling pathogen elimination without compromising the breathability of the mechanical filtration layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a mask incorporates a liquid-carrying layer with antimicrobial agents, then it can kill pathogens in exhaled air, but it may increase airflow resistance and reduce breathability

Engineering Contradiction:

Improvepathogen elimination effectivenessVSAvoidbreathing energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The liquid-carrying layer is positioned specifically between the inner and outer mechanical filtration layers, creating a localized antimicrobial zone. This allows the majority of the mask structure to maintain its breathability while concentrating pathogen-killing function in a specific region where it is most needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The liquid-carrying layer is designed with porous characteristics that allow air to pass through while retaining the liquid antimicrobial agents. This enables the layer to provide pathogen elimination functionality without creating significant airflow resistance, thus maintaining breathability.

Inventive Principle:

Principle #31Porous materials

3Reliability

If a mask uses multiple layers including a liquid-carrying layer, then it provides both mechanical filtration and antimicrobial action, but it increases the complexity of mask construction and liquid distribution

Engineering Contradiction:

Improvecomprehensive protection effectivenessVSAvoidmask assembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mask is divided into distinct functional layers: outer mechanical filtration layer, intermediate liquid-carrying layer, and inner mechanical filtration layer. This segmentation allows each layer to be optimized and manufactured separately, then assembled together, simplifying the overall manufacturing process while achieving comprehensive protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The liquid-carrying layer is pre-saturated with antimicrobial agents before final mask assembly. This preliminary action ensures uniform distribution of the liquid throughout the layer, eliminating the need for complex liquid distribution mechanisms during or after mask assembly, thus simplifying manufacturing.

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 sanitizing face mask effectively reduces the transmission of airborne pathogens by mechanically trapping droplets and killing microbes with the sanitizing liquid, protecting both the wearer and others from infection.

Implementation Method 1

intermediate layer (14) appointed to absorb the sanitizing liquid

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

sanitizing liquid capable of killing pathogens contained in the air passing through the mask

Methodology Applied

Scientific EffectAntimicrobial action:

Implementation Method 3

masks are constructed with one or more layers of a woven or non-woven, fabric-like material or a fibrous, paper-like material. The mask is intended to inhibit the passage of pathogens into or out of the nose and mouth of the wearer

Methodology Applied

Scientific EffectMechanical filtration: Filter (physical)

Data Source

PatentUS12295432B2Sanitizing face mask

Publication Date: 2025.05.13 LEWIS RANDALL J

AI summary

A sanitizing face mask inhibits the transmission of pathogens in air respired through the nose and mouth of a wearer. The mask includes hydrophobic inner and outer layers and an intermediate layer enclosed between them. The intermediate layer is saturated with a sanitizing liquid such as an ethanol solution. Respired air encounters the sanitizing liquid as it passes through the intermediate layer, killing pathogens borne on droplets or aerosols. The sanitizing mask protects the wearer, from pathogens in the inspired air, and others, from possible pathogens in the expired air of the wearer.