CPAP Mask Cushion Channel with Partial Bead
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Solution Overview
Problem
Current respiratory masks for treating obstructive sleep apnea are not efficient in terms of flow requirements, noise levels, manufacturing costs, ease of assembly, and aesthetics, and require improvements in design to enhance user experience.
Innovation Solution
The design incorporates a mask frame with a streamlined neck, a channel for the cushion with a bead for secure attachment, a recessed port structure to reduce 'rainout', a forehead support with slotted connectors for aesthetics, an elbow with a baffle for improved gas washout efficiency, and a vented cover with patterned holes to decrease noise and fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full bead is used around the entire channel perimeter, then cushion attachment security is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies partial action by providing the bead only along selected portions of the channel perimeter rather than the entire perimeter. The bead is positioned to engage the cushion edge at critical locations while omitting it from other areas, thereby achieving sufficient cushion attachment security while reducing manufacturing complexity and cost.
2Productivity
If more flow is required for effective treatment, then treatment effectiveness is improved, but noise levels and energy consumption increase
Solution Approach 1:
The patent optimizes flow parameters by designing the channel with specific geometric parameters including the partial bead configuration, channel cross-sectional area, and surface roughness characteristics. These parameter changes enable effective treatment at reduced flow rates, thereby decreasing noise levels and energy consumption while maintaining treatment effectiveness.
3Strength
If the neck structure is made more substantial for strength, then structural integrity is improved, but obtrusiveness and aesthetics worsen
Solution Approach 1:
The patent applies local quality by varying the neck structure's properties in different locations. The neck has increased thickness and reinforcement at specific locations where structural integrity is critical, while maintaining a slender, streamlined profile in visible areas. This localized strengthening approach preserves both structural integrity and aesthetic appearance.
4Ease of operation
If the port structure is raised for easier access, then ease of operation is improved, but rainout increases
Solution Approach 1:
The patent resolves this contradiction by transitioning from a vertical positioning approach to a horizontal/dimensional approach. The port structure is recessed into the frame, creating a protected cavity that shields the port from moisture condensation (rainout) while maintaining easy access through the recessed design that allows finger access into the recessed area.
Data Source
AI summary
A mask assembly adapted for use with a positive airway pressure device, includes a mask frame, an elbow assembly provided to the frame, a cushion provided to the frame, a forehead support assembly, and a neck to connect the frame to the forehead support assembly, wherein the neck includes a pair of side walls having a streamlined design that is made to look sleek and reduce or minimize obtrusiveness. The pair of side walls may take the form of a single wall or more than two walls. The mask frame may include a recessed port structure including at least one port having access to an interior of the frame which at least in part with the cushion defines a breathing chamber in communication with a nasal passage of the patient in use. The mask frame may also include a channel to receive the cushion. The channel is formed by an outer wall and an inner wall and the channel includes an inner surface having a bead to engage with an outer surface of an edge of the cushion. The forehead support assembly includes a forehead support and a forehead pad coupled to the forehead support. The elbow assembly includes an elbow connectable to the mask frame. A cover is releasably connectable to the elbow. The cover includes a venting area including a plurality of vent holes.