Customizable respiratory mask
A customizable mask, and methods of forming such a mask, including a conforming seal is configured to utilize the physical process of granular jamming to enable it to adapt to a wide range of facial geometries. The mask may include a frame having a perimeter and a conduit connection, a conforming seal positioned along the perimeter of the frame; the conforming seal may include a sealing surface and a connecting surface, the connecting surface configured to mate with the perimeter of the frame, and the sealing surface configured to conform to a users' face. The conforming seal may further include an outer casing, granular material contained within the outer casing, and a vacuum connection. The mask may also include a similarly configured conforming frame.
1 . A respiratory mask able to fit a plurality of differently-shaped human faces, the respiratory mask comprising:
a frame portion comprising a perimeter portion and a conduit connection portion;
a seal portion connected to the perimeter portion of the frame portion, the seal portion comprising a sealing surface and a connecting surface, the connecting surface being connected to the perimeter portion, the sealing surface able to form a seal with a portion of a human face;
a granular chamber located in the seal portion and containing a granular material, the granular chamber configured to be transitioned between a conforming state and a fixed state;
a vacuum connection port in the seal portion;
a vacuum connection conduit connected to the vacuum connection portion and configured to allow a vacuum to be applied to the granular chamber through the vacuum connection port to transition the granular chamber from the conforming state to the fixed state;
at least one internal structure within the granular chamber that is separate from and surrounded by the granular material, and is separate from and spaced apart from the vacuum connection port and the vacuum connection conduit, wherein the granular material is positioned between the vacuum connection port and the at least one internal structure, the at least one internal structure having a first surface and a second surface opposite the first surface, wherein the granular material acts on a surface area of each of the first surface and the second surface of the at least one internal structure to provide a reaction force that is able to provide controlled deformation to the respiratory mask in response to the granular chamber transitioning from the conforming state to the fixed state.
2 . The respiratory mask of claim 1 , whereby compressing the seal portion results in the at least one internal structure pulling sides of the seal portion inwards towards a nose of the human face.
3 . The respiratory mask of claim 1 , whereby in the conforming state, the seal portion is able to deform and conform to facial geometry of the human face.
4 . The respiratory mask of claim 1 , wherein in the fixed state, the seal portion retains a geometry that was established in the conforming state.
5 . The respiratory mask of claim 1 , wherein the at least one internal structure is configured such that at least a portion of the granular material moves around and past the at least one internal structure when the seal portion is deformed.
6 . The respiratory mask of claim 1 , wherein the at least one internal structure is suspended in a central position within the granular chamber of the seal portion.
7 . The respiratory mask of claim 1 , wherein the at least one internal structure resists contacting a membrane of the seal portion.
8 . The respiratory mask of claim 1 , wherein the at least one internal structure is flexible and inelastic.
9 . The respiratory mask of claim 1 , wherein the at least one internal structure has a length and defines a cross-sectional shape that extends along the length, wherein the length of the at least one internal structure extends along a longitudinal length of the seal portion, and wherein the first surface and the second surface are separated from one another by a thickness of the cross-sectional shape.
10 . The respiratory mask of claim 9 , wherein the first surface faces toward the frame portion and the second surface faces away from the frame portion.
11 . The respiratory mask of claim 1 , wherein the at least one internal structure is an internal skeleton.
12 . The respiratory mask of claim 11 , wherein the internal skeleton comprises a pitchfork shaped cross-section.
13 . The respiratory mask of claim 11 , wherein the internal skeleton extends longitudinally within the seal portion.
14 . The respiratory mask of claim 11 , wherein the granular chamber forms an annular loop, wherein the internal skeleton extends around and along an entire length of the annular loop within the granular chamber.
15 . The respiratory mask of claim 11 , wherein the internal skeleton is able to constrict movement of the granular material within the seal portion.
16 . The respiratory mask of claim 1 , wherein the at least one internal structure is of a non-granular material.
17 . The respiratory mask of claim 1 , wherein the sealing surface extends along an entire length of the seal portion and is configured to encircle one or both nostrils and/or a mouth of the human face, wherein the at least one internal structure forms an annular loop around and along the entire length of the seal portion.
18 . The respiratory mask of claim 1 , wherein the controlled deformation comprises an inducement of a clam-shelling movement.
19 . A respiratory mask able to fit a plurality of differently-shaped human faces, the respiratory mask comprising:
a frame portion comprising a perimeter portion and a conduit connection portion;
a seal portion connected to the perimeter portion of the frame portion, the seal portion formed of a seal material and comprising a sealing surface and a connecting surface, the connecting surface being connected to the perimeter portion, the sealing surface forming a loop to encircle an interior space that is configured to receive one or both nostrils and/or a mouth of the human face and able to form a seal with a portion of a human face, the seal portion further comprising an inner wall defining a portion of the interior space and an outer wall on an opposite side of the sealing surface from the inner wall, the outer wall is configured to face an outside of the respiratory mask when the respiratory mask is being worn by the user;
a granular chamber located in the seal portion and containing a granular material, the granular chamber configured to be transitioned between a conforming state and a fixed state;
at least one structural layer within the granular chamber that is separate from and surrounded by the granular material, wherein the at least one structural layer extends from the inner wall of the seal portion to the outer wall of the seal portion, the at least one structural layer having a thickness defined between a first surface and a second surface opposite the first surface;
wherein the at least one structural layer is more rigid than the inner wall and the outer wall of the seal portion;
wherein the granular material acts on a surface area of each of the first surface and the second surface of the at least one structural layer to provide a reaction force that is able to provide controlled deformation to the respiratory mask in response to the granular chamber transitioning from the conforming state to the fixed state.
20 . The respiratory mask of claim 19 , wherein the at least one structural layer is formed of the seal material, wherein the thickness of the at least one structural layer is greater than each of a thickness of the inner wall and a thickness of the outer wall.
21 . A respiratory mask able to fit a plurality of differently-shaped human faces, the respiratory mask comprising:
a frame portion comprising a perimeter portion and a conduit connection portion;
a seal portion connected to the perimeter portion of the frame portion, the seal portion comprising a sealing surface and a connecting surface, the connecting surface being connected to the perimeter portion, the sealing surface able to form a seal with a portion of a human face;
a granular chamber located in the seal portion and containing a granular material, the granular chamber configured to be transitioned between a conforming state and a fixed state;
at least one internal structure within the granular chamber that is separate from and surrounded by the granular material, the at least one internal structure having a first surface and a second surface opposite the first surface, wherein the granular material acts on a surface area of each of the first surface and the second surface of the at least one internal structure in response to deformation of the frame portion, and generates a reactionary force that is able to provide controlled deformation to the seal portion of the respiratory mask;
wherein the controlled deformation comprises translation of deformation in a height dimension of the seal portion to movement or deformation in a width dimension of the seal portion, or vice-versa, as a result of the reactionary force generated by the at least one internal structure acting on the granular material, wherein the at least one internal structure is an internal skeleton, and the granular chamber forms an annular loop, wherein the internal skeleton extends around and along an entire length of the annular loop within the granular chamber.