Custom Contour Support for Patient Interface Cushion Seal

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Solution Overview

Problem

Cradle style patient interface devices face challenges in maintaining a reliable seal due to sensitivity to alignment and external forces, leading to compromised airflow and discomfort from air leakage.

Innovation Solution

A custom cushion support assembly with a contoured surface that deforms to match the patient's sub-nasal area, providing a more complete seal by aligning with the device's passages and supporting a resilient cushion for improved fit and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional cradle style sealing cushion is used, then the device structure is simple, but the seal quality is poor and sensitive to alignment

Engineering Contradiction:

Improveseal qualityVSAvoidcushion support assembly

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cushion support assembly is divided into multiple components: a cushion body with an engagement portion, a support assembly with a custom contour, and a pocket structure. This segmentation allows each component to perform its specific function - the cushion provides sealing, the support assembly provides alignment and stability, and the pocket holds the support assembly in place.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support assembly acts as an intermediary between the cushion body and the patient's sub-nasal area. It includes a custom contour that interfaces with the cushion's engagement portion and provides alignment features that ensure proper positioning on the patient's face, thereby improving seal quality without requiring direct cushion-to-face contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the cushion alignment is not precise, then the device is easy to wear, but air leakage occurs and discomfort increases

Engineering Contradiction:

Improvedevice wearabilityVSAvoidair leakage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The support assembly includes alignment features and a custom contour that are pre-configured to guide the cushion into proper alignment with the patient's sub-nasal area. This preliminary alignment structure ensures that the cushion is correctly positioned before use, preventing air leakage and discomfort while maintaining ease of wear.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support assembly modifies the geometric parameters of the cushion positioning system by introducing a custom contour with specific curvature and orientation. This changes the alignment parameters from arbitrary to controlled, ensuring consistent proper positioning while maintaining comfort and preventing air leakage.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If external forces act on the mask, then the mask is flexible and comfortable, but the seal alignment is disrupted

Engineering Contradiction:

Improvemask flexibilityVSAvoidseal alignment

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The cushion body is made from a flexible material that can deform to conform to the patient's sub-nasal area. This flexible shell maintains comfort and adaptability while the integrated support assembly provides structural stability to maintain seal alignment against external forces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The support assembly features an asymmetric custom contour design that is specifically shaped to resist external forces from different directions. The asymmetric geometry provides enhanced stability in the critical sealing direction while allowing flexibility in other directions for comfort.

Inventive Principle:

Principle #4Asymmetry

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

Enhances the seal quality between the cushion and the patient's nose, reducing air leakage and discomfort, and ensuring consistent airflow during respiratory therapy.

Implementation Method 1

custom cushion support assembly body upper surface custom contour deforms patient interface device cushion body engagement portion to correspond to patient's sub-nasal area

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

Cushion includes a resilient body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10881825B2Sealing cushion for a patient interface device that has a custom cushion support assembly

Publication Date: 2021.01.05 KONINKLIJKE PHILIPS NV

AI summary

A patient interface device (8) structured to engage a patient's sub-nasal area is provided and includes a body (22), a cushion (50) and a custom cushion support assembly (100). Patient interface device body includes a sidewall (27) with an upper side (32) including a number of passages (40). Cushion includes a resilient body (52). Cushion body is disposed on patient interface device body. Patient interface device cushion body includes an engagement portion (60) structured to engage a patient's sub-nasal area, and a pocket (70) disposed under cushion body engagement portion. Custom cushion support assembly includes a body (102) with an upper surface (104) including a custom contour (110). Custom cushion support assembly body is disposed in patient interface device cushion body pocket. In this configuration, custom contour deforms patient interface device cushion body engagement portion to correspond to patient's sub-nasal area.