Cushion to Frame Assembly Mechanism for Full-Face Masks
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Solution Overview
Problem
Existing assembly mechanisms for patient interfaces used in treating sleep disordered breathing, such as obstructive sleep apnea, face challenges with alignment and assembly, adhesive issues that prevent disassembly for cleaning, and overmolded parts with difficult-to-clean ingress points, particularly on large frames like full-face masks.
Innovation Solution
A cushion-to-frame assembly mechanism featuring a flexible lip on the cushion interior wall that forms a seal with the frame, integrated with frame mating geometry, including angled slots and retaining recesses, and a skeleton frame with interlocking protrusions and tabs, allowing for easy assembly, disassembly, and cleaning, while providing a compliant seal to reduce leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive methods are used to secure the cushion to the frame, then the assembly is strong and secure, but disassembly for cleaning becomes difficult or impossible
Solution Approach 1:
The assembly mechanism is divided into separate components: a cushion with an integrally molded retaining portion and a frame with a corresponding retaining feature. This segmentation allows the cushion to be securely attached during use while enabling easy disassembly for cleaning by simply releasing the retaining mechanism.
2Strength
If overmolded parts are used to secure the cushion, then the assembly is durable and secure, but ingress points remain that are difficult to clean
Solution Approach 1:
The design extracts the cushion from the frame cavity rather than embedding it within an overmolded structure. The cushion is retained by the integrally molded retaining portion that engages with the frame's retaining feature, eliminating hidden ingress points where dirt could accumulate while maintaining secure attachment.
3Strength
If interference methods are used for large frames, then the cushion is secured firmly, but alignment and assembly become difficult
Solution Approach 1:
The retaining portion is integrally molded onto the cushion during manufacturing, pre-forming the alignment features before assembly. The frame includes a corresponding retaining feature with a slot that guides the retaining portion into proper alignment, making assembly straightforward while ensuring firm securing.
4Ease of operation
If multiple separate components are used for assembly, then disassembly for cleaning is enabled, but alignment and assembly difficulty increase
Solution Approach 1:
The retaining portion is integrally molded as a single piece with the cushion, combining the cushion and retaining features into one component. This merging reduces the number of separate parts that need to be assembled while still enabling easy disassembly for cleaning when needed.
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 solution facilitates simple and effective assembly and disassembly, ensures a secure and leak-resistant seal, and allows for easy cleaning, addressing the limitations of existing mechanisms by improving alignment, disassembly, and cleanliness on various frame sizes, including full-face masks.
Implementation Method 1
a flexible lip provided to an interior wall of the cushion. The flexible lip is adapted to engage the frame to provide a seal in use
Data Source
AI summary
A full-face mask assembly includes a frame and a cushion provided to the frame. The cushion is adapted to form a seal around the patient's nose and mouth. A flexible lip is provided to an interior wall of the cushion. The flexible lip is adapted to engage the frame to provide a seal in use.