Two-Color Molded Respiratory Mask Anti-Slip Grip Design

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Solution Overview

Problem

Existing three-plate molds for injection molding are costly, voluminous, and produce significant residue, with a complex structure that results in low structural strength and high weight.

Innovation Solution

A two-color molded anti-slip grip respiratory mask is created using a two-plate mold, where the mask body is injection molded from a hard polypropylene composition and a buffer member from a softer thermoplastic rubber composition, with a mold design that includes male and female molds to form the mask body and buffer member separately.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a three-plate mold is used for injection molding, then the mask body can be formed with complex geometry, but the mold cost increases, volume increases, and structural strength decreases

Engineering Contradiction:

Improvemask body geometryVSAvoidmold structure

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The mold is divided into three distinct plates: a fixed plate for maintaining structural strength, a movable plate for enabling complex geometry formation, and an ejection plate for product removal. This segmentation allows each plate to have specialized functions, resolving the contradiction between structural strength and geometric complexity capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The movable plate and ejection plate are nested within the fixed plate structure, with the movable plate positioned between the fixed plate and ejection plate. This nesting arrangement consolidates multiple functions into a compact configuration, reducing overall mold volume while maintaining the ability to form complex geometries.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If a three-plate mold is used for injection molding, then the mask body can be formed with complex geometry, but the mold weight increases

Engineering Contradiction:

Improvemask body geometryVSAvoidmold weight

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

3Shape

If a three-plate mold is used for injection molding, then the mask body can be formed with complex geometry, but the production cost increases

Engineering Contradiction:

Improvemask body geometryVSAvoidmold cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

4Shape

If a three-plate mold is used for injection molding, then the mask body can be formed with complex geometry, but the residue amount increases

Engineering Contradiction:

Improvemask body geometryVSAvoidresidue amount

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The ejection plate is extracted as a separate, dedicated component with specialized ejection pins and channels designed specifically for residue removal. This separate ejection system efficiently extracts residue from the injection channels and mold cavities, reducing waste material while maintaining complex geometry formation capability.

Inventive Principle:

Principle #2Taking out (Extraction)

5Ease of operation

If the buffer member has small hardness, then the comfort during application is improved, but the grip strength decreases

Engineering Contradiction:

Improvecomfort during applicationVSAvoidgrip strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The buffer member is designed with locally varied hardness: the portion contacting the patient's face has small hardness for comfort, while the grip portion has increased hardness for secure handling. This local quality differentiation resolves the contradiction between comfort and grip strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The buffer member is constructed as a composite structure with different material properties in different regions - a softer material for the facial contact area and a harder material for the grip area, or a single material with spatially varying hardness. This composite approach allows simultaneous achievement of comfort and grip strength.

Inventive Principle:

Principle #40Composite materials

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 two-plate mold design reduces production costs, minimizes residue, and enhances structural strength while providing an anti-slip grip for respiratory masks, improving usability and reducing discomfort during application.

Implementation Method 1

the mask body is injection molded from a first composition and a buffer member from a second composition

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20250170352A1Two-color molded Anti-slip grip respiratory mask and mold therefor

Publication Date: 2025.05.29 HSINER

AI summary

A respiratory mask includes a mask body injection molded from a first composition, and a buffer member injection molded from a second composition and connected to and surrounding the mask body. The mask body includes a shield portion having an air inlet, a flange extending outwardly from the shield portion, and a grip portion cooperating with the flange and the shield portion to define a receiving groove. The shield portion further defines a facial space communicating with the air inlet. The flange has an inner surface proximate to the facial space, and an outer surface opposite to the inner surface. The grip portion protrudes from the outer surface of the flange. A mold for making the two-color molded anti-slip grip respiratory mask is also disclosed.