CPAP Mask Seal Assembly with Thin Bridge and Baffle
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Solution Overview
Problem
Existing respiratory masks used for CPAP therapy in obstructive sleep apnea patients often cause discomfort due to poor fit, noise from gas vents, and pressure sores, leading to user intolerance and suboptimal therapeutic outcomes.
Innovation Solution
A patient interface with a mask assembly featuring a flexible seal and rigid clip system that provides a positive snap engagement, a thin bridge section in the nasal bridge region for reduced pressure, and a baffle arrangement in the connector to minimize noise, along with a headgear system for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional respiratory mask is used to provide a seal around the user's face, then gas leakage is prevented, but user discomfort increases and tolerance decreases
Solution Approach 1:
The mask is divided into separate functional components: a rigid mask body, a flexible seal element, and a headgear system. This segmentation allows each component to be optimized independently - the rigid body provides structural support while the flexible seal adapts to facial contours, resolving the contradiction between seal integrity and comfort
Solution Approach 2:
A flexible seal element is introduced between the rigid mask body and the user's face. This flexible component conforms to facial irregularities and movements, maintaining seal integrity without requiring excessive tightening that would cause discomfort
2Reliability
If a vent is provided for washout of expired gases, then carbon dioxide buildup is prevented, but excessive noise is generated
Solution Approach 1:
A baffle structure is introduced as an intermediary element in the gas flow path. The baffle redirects and diffuses the expiratory gas flow, enabling effective washout of carbon dioxide while reducing turbulence-induced noise to acceptable levels
Solution Approach 2:
The vent design is modified to change flow parameters - the baffle structure alters gas flow velocity and direction, distributing the flow more evenly and reducing peak velocities that generate noise, while maintaining sufficient flow for CO2 washout
3Power
If concentrated air flow is provided in the respiratory tract, then breathing assistance is delivered, but oral cavity dehydration and irritation occur
Solution Approach 1:
The mask design incorporates localized features such as cheek cushions and strategically positioned seal elements that redirect and distribute air flow away from the oral cavity. This creates different local flow conditions - sufficient pressure support in the nasal airway while minimizing direct concentrated flow over the mouth to prevent dehydration
4Reliability
If mask tightening is increased to improve seal, then seal integrity is improved, but pressure sores are caused
Solution Approach 1:
The flexible seal element distributes masking force over a larger area and adapts to facial contours, achieving adequate seal integrity at lower tightening forces, thereby preventing pressure sores
Solution Approach 2:
Cushioning elements are strategically placed in areas prone to pressure sores (such as the nasal bridge and cheek regions) to distribute and reduce localized pressure before it can cause tissue damage
Data Source
AI summary
A breathing assistance apparatus is disclosed, for use with delivery of respiratory gases to a patient. The breathing assistance apparatus includes a patient interface, having a body section adapted to cover the nose, or nose and mouth of a patient and a sealing interface. The sealing interface includes at least an outer sealing member. The outer sealing member is adapted to attach to the body section in a sealing manner and has a substantially thin section in at least its nasal bridge region. The thin section is substantially thinner than the rest of the outer sealing member.The patient interface comprises a mask body and a seal assembly. The seal assembly includes a flexible seal, and a rigid seal clip, the seal assembly being removably attached to the mask body via the rigid seal clip. The mask body and rigid seal clip are profiled to match the contours of a user's face so that the seal has a substantially constant wall depth.