Co-Molded Cushion Module for Stable CPAP Mask Sealing
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Solution Overview
Problem
Existing patient interfaces for treating sleep disordered breathing lack comfort and fit, leading to reduced therapy efficacy and compliance.
Innovation Solution
A mask system without a forehead support, featuring a frame and shroud co-molded with a cushion, where the frame is more rigid and the shroud is more flexible, with stabilizing mechanisms like upper and lower headgear connectors to maintain the mask's position, ensuring a secure seal without obstructing the patient's field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a forehead support is included in the mask system, then stability and seal are improved, but comfort and field of view are worsened
Solution Approach 1:
The patent removes the forehead support component from the mask system entirely. The headgear connectors are repositioned to attach directly to the frame at locations that provide sufficient stabilization without requiring a forehead support, thereby eliminating the obstruction to the patient's field of view and improving comfort.
2Strength
If the frame is made more rigid, then structural stability is improved, but comfort and adaptability to face contours are worsened
Solution Approach 1:
The frame is designed with varying degrees of rigidity in different regions. The main structural portions maintain sufficient rigidity for stability, while specific areas incorporate flexibility to adapt to face contours and provide comfort. The headgear connectors are positioned at strategic locations where rigidity provides stabilization without requiring uniform rigidity throughout the entire frame.
3Ease of operation
If headgear connectors are repositioned away from forehead, then comfort and field of view are improved, but stability may be worsened
Solution Approach 1:
The headgear connectors are repositioned from the forehead area to alternative locations on the frame structure. This spatial redistribution maintains mask stability through proper structural geometry and load distribution while eliminating the comfort issues and field of view obstruction associated with forehead supports.
Data Source
Figure 1
Figure 1B
Figure 1C~1D
AI summary
The present invention discloses a cushion module for a patient interface for treatment of a respiratory disorder in a patient with a supply of air at continuously positive pressure, the cushion module comprising a cushion constructed from a first material, the cushion being adapted to form a seal with the patient's face in use; and a frame molded from a second material that is more rigid than the first material of the cushion, the frame defining a breathing chamber in use, the frame comprising a collar surrounding a frame opening, and the collar having a snap-fit structure that is configured to releasably engage a shroud of the patient interface and extends in an annular direction of the collar, wherein the frame and the cushion are co-molded with one other such that the cushion module is a one-piece, integrated component.