Seamless Elastomer Pad Core Shell for Respirator Carrying Belt
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Solution Overview
Problem
Existing carrying belt systems for respirators face challenges in manufacturing complexity, cost, and moisture penetration due to sewing of textile shells, which affects comfort and decontamination efficiency.
Innovation Solution
A process involving injection molding of a hollow profiled section to create a seamless, elastomer-based pad core shell with a closed, hermetically sealed structure, eliminating the need for sewing and incorporating a belt strap connection device as an integral component, allowing for faster, cost-effective, and more robust manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If textile shells are sewn together to enclose the elastic core, then the padding device is simple to manufacture, but the moisture barrier is damaged and moisture can penetrate between the core and shell
Solution Approach 1:
The patent replaces the mechanical sewing process with a chemical bonding process using adhesive. The adhesive is applied to bond the textile shell to the elastic core, eliminating the need for sewing needles and threads that create puncture holes. This substitution maintains manufacturing simplicity while preserving the moisture barrier integrity, as the adhesive creates a continuous seal without the holes created by stitching.
Solution Approach 2:
The patent changes the bonding method from mechanical (sewing) to chemical (adhesive bonding). This parameter change in the joining process allows the moisture barrier layer to remain intact, as adhesive bonding does not require penetrating the material with needles like sewing does. The chemical bonding process maintains the continuity of the moisture barrier while achieving the same structural assembly function.
2Ease of manufacture
If textile shells are sewn together, then the padding device is simple to manufacture, but the drying process lasts for a relatively long time
Solution Approach 1:
The patent replaces mechanical sewing with adhesive bonding, which eliminates the holes created by stitching. Without these holes, moisture cannot penetrate into the elastic core, thereby eliminating the prolonged drying time associated with removing moisture from sewn constructions. The adhesive creates a seamless barrier that prevents moisture ingress while maintaining manufacturing simplicity.
3Ease of manufacture
If textile shells are sewn together, then the padding device is simple to manufacture, but it is not possible to remove harmful substances without residues from the area between the core and shell
Solution Approach 1:
The patent replaces mechanical sewing with adhesive bonding, creating a seamless interface between the textile shell and elastic core. This eliminates the needle holes and stitching channels that trap contaminants. The smooth, continuous surface created by adhesive bonding allows for complete decontamination without residues, as there are no hidden crevices or holes where harmful substances could be trapped, while maintaining manufacturing simplicity.
4Strength
If thermoformed elastomer-coated parts are brought together with foam in a mold, then the carrying belt system is robust, but the configuration is complicated and many process steps are needed
Solution Approach 1:
The patent merges the textile shell, elastic core, and moisture barrier layer into a single integrated construction using adhesive bonding. Instead of assembling multiple separate components through molding and sewing operations, the adhesive bonds these layers together in a simplified process. This merging maintains the robustness of the elastomer-coated construction while significantly reducing configuration complexity and the number of manufacturing process steps.
Solution Approach 2:
The adhesive bonding process serves multiple functions simultaneously: it bonds the textile shell to the elastic core, seals the moisture barrier layer, and creates a smooth surface for decontamination. This multi-functional approach replaces the need for separate molding, sewing, and sealing operations, thereby reducing device complexity while maintaining the robustness of the elastomer construction.
5Strength
If thermoformed elastomer-coated parts are brought together with foam in a mold, then the carrying belt system is robust, but many process steps are needed to manufacture
Solution Approach 1:
The patent combines multiple manufacturing operations into a single adhesive bonding process. Instead of separately molding elastomer parts, assembling them with foam, and then sewing textile shells, the adhesive bonds these components together in one step. This merging of operations maintains the robustness of the elastomer construction while significantly improving manufacturing efficiency by reducing the total number of process steps and cycle time.
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 simplifies and cost-reduces the manufacturing of padding devices, enhances fire resistance, and facilitates quick drying and decontamination by creating a seamless, liquid-tight and gastight pad core shell, while providing a secure and comfortable carrying belt system for respirators.
Implementation Method 1
injection molding of a hollow profiled section
Implementation Method 2
insertion of a pad core material into the hollow profiled section for forming a pad core in the hollow profiled section
Implementation Method 3
closing of the hollow profiled section for creating the closed pad core shell
Data Source
AI summary
A padding device (10a; 10b; 10c; 10d; 10e), for a carrying belt system (100) for a respirator (1000), has a closed pad core shell (20) and a pad core (30) configured in the pad core shell. The padding device is formed by injection molding a hollow profiled section, inserting of a pad core material into the hollow profiled section for forming the pad core in the hollow profiled section, and closing the hollow profiled section (21) for creating the closed pad core shell (20). The padding device (10a; 10b; 10c; 10d; 10e) has a closed pad core shell (20) and a pad core (30) arranged in the pad core shell. The pad core shell is seamless as an injection-molded component in at least some sections. A carrying belt system and a respirator with the carrying belt system are provided with the belt system having the padding device.