Thermoformable Respiratory Mask Inserts for Face Seal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current respiratory protection devices face challenges in creating a secure seal around the face, especially during talking or moving, and in providing improved breathability while protecting against respiratory aerosols that may contain infectious diseases.
Innovation Solution
The respiratory protection device incorporates a shell with thermoformable inserts made of materials like polypropylene and thermoplastic polyurethane, which can be heated to create a moldable seal around the face, combined with a filter medium featuring a pleated surface for enhanced fit and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a respiratory protection device uses a rigid shell structure, then structural strength and protection are improved, but breathability and comfort deteriorate
Solution Approach 1:
The patent applies flexible membranes as breathing elements within the rigid shell structure. These membranes allow gas exchange while maintaining the structural integrity of the shell, thus improving breathability without compromising strength
Solution Approach 2:
The patent incorporates porous filtering materials that allow air passage while blocking respiratory aerosols. The porous structure enables breathability while maintaining protective function, resolving the contradiction between ventilation and protection
2Reliability
If a respiratory protection device uses a thermoformable insert to create a secure seal, then sealing reliability is improved, but device complexity and manufacturing difficulty worsen
Solution Approach 1:
The patent uses thermoformable materials that change their physical state or shape in response to temperature changes. The insert is heated to a moldable temperature, shaped to fit the user's face, then cooled to set the seal, achieving reliable sealing through parameter change rather than complex mechanisms
Solution Approach 2:
The thermoformable insert is pre-formed in a mold to create the sealing surface before being installed in the device. This preliminary action simplifies the overall device structure by pre-preparing the sealing component rather than requiring complex in-situ forming mechanisms
3Ease of operation
If a respiratory protection device uses a thermoformable insert, then breathability and comfort are improved, but manufacturing precision and temperature control requirements worsen
Solution Approach 1:
The patent specifies a temperature range (30°C to 70°C) for forming the thermoformable insert, allowing flexibility in manufacturing while ensuring proper material behavior. This range-based approach reduces the stringency of precise temperature control requirements compared to single-point temperature specifications
4Object-affected harmful factors
If a respiratory protection device creates a tight seal around the face, then protection against aerosols is improved, but breathability and user comfort worsen
Solution Approach 1:
The patent incorporates porous filtering materials that create a tight seal to block aerosols while their porous structure allows air passage. The filtering medium with controlled porosity enables simultaneous achievement of sealing protection and breathability
Solution Approach 2:
The patent combines different materials with complementary properties: rigid shell for structure, thermoformable material for sealing, and porous filtering material for breathability. This composite approach allows the device to achieve both tight sealing for protection and adequate ventilation
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
This design ensures a secure seal and improved breathability, effectively preventing the spread of respiratory aerosols and protecting users from inhalation of harmful particles, while being safe for skin contact and reusable.
Implementation Method 1
the one or more inserts are capable of being heated to a moldable temperature of the thermoformable material
Implementation Method 2
a filter medium featuring a pleated surface for enhanced fit and breathability
Data Source
AI summary
A respiratory protection device can be used to cover a portion of a face of a human user including the mouth or the nostrils of the user, or both. The device can include a shell and inserts embedded therein. The inserts can be formed of a thermoformable material embedded in the shell. The inserts are capable of being heated to a moldable temperature of the thermoformable material and form-fitted to a portion of the face of the user such that the shell creates a seal around at least the mouth or the nostrils of the user. Also, the thermoformable material can be moldable at a temperature safe to contact skin of the user such as by having a Young's modulus from a range of 0.03 GPa to 1 GPa at temperatures of less than 30° C. Also, the device can include a filter medium attached to the shell.