CPAP Mask Assembly with Flapper Valves for Mouth Leak Prevention
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Solution Overview
Problem
CPAP masks, particularly nasal masks, often lead to dry mouth and leakage issues due to air pressure escaping through the nose and mouth, causing discomfort and leading to patients discontinuing therapy, which can result in health complications such as tooth decay, bad breath, and sleep apnea-related issues.
Innovation Solution
A mask assembly with a substrate covering the mouth, featuring a diaphragm with intersecting slits forming flapper valves that allow inhalation while preventing exhalation, and a peripheral seal to create a sealed air chamber, directing exhaled air through the nose, thus maintaining continuous positive airway pressure and preventing mouth leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nasal mask is used to deliver pressurized air, then continuous positive airway pressure is maintained, but air escapes through the mouth causing dry mouth and leakage
Solution Approach 1:
The mask system is divided into two separate components: a nasal mask for delivering pressurized air and a mouth mask with one-way valves to prevent exhalation leakage. This segmentation allows each component to perform its specific function optimally without interfering with the other.
Solution Approach 2:
One-way valve assemblies act as intermediaries between the pressurized air source and the user's mouth. These valves allow inhalation of pressurized air while blocking exhaled air, thereby preventing mouth leakage without directly blocking the nasal air delivery path.
2Reliability
If the mask covers the mouth to prevent leakage, then mouth leaks are reduced, but inhalation is restricted
Solution Approach 1:
The one-way valve assemblies are designed to dynamically respond to pressure differentials: they remain closed during exhalation to prevent leakage but automatically open during inhalation to allow air flow. This dynamic behavior maintains seal effectiveness while ensuring breathing comfort.
Solution Approach 2:
The valve mechanism converts the potentially harmful effect of mouth coverage (restricting breathing) into a beneficial effect by selectively permitting inhalation while blocking exhalation. The restriction becomes useful by directing exhaled air through the nose while allowing unobstructed inhalation.
3Reliability
If pressurized air is delivered continuously, then airway remains open, but exhaled air escapes through mouth causing discomfort
Solution Approach 1:
Instead of trying to block the mouth to prevent exhaled air escape (which would restrict inhalation), the invention inverts the approach by using one-way valves that actively direct exhaled air through the nose while permitting inhalation. This inversion transforms the mouth from a potential leakage path into a controlled exhalation route.
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 mask assembly effectively prevents dry mouth and mouth leaks, minimizing symptoms like tooth decay and improving sleep quality, which can lead to better health outcomes and longer life expectancy by maintaining continuous positive airway pressure during sleep.
Implementation Method 1
The valve seal is formed from a flexible material to permit elastic deformation of the flaps to open the valves, and retraction of the flaps to close the valves.
Data Source
AI summary
A mask assembly is provided with a substrate sized to cover a mouth of a user. A plurality of ports is formed through the substrate. A valve seal is mounted to the substrate. The valve seal has a plurality of valves formed through the valve seal. A peripheral seal is mounted to the substrate to seal around the valve to seal the substrate and the valve seal to a face of the user around the mouth of the user.