Customizable Airway Mask Frame With Deformable Fit Zones

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Solution Overview

Problem

Existing mask fitting solutions for treating sleep disordered breathing are either costly and time-consuming or inadequate for individuals with non-typical facial geometries, and current custom masks lack flexibility for re-customization.

Innovation Solution

A customizable mask with deformable zones and removable inserts, allowing for quick and cost-effective customization and re-customization based on user facial dimensions, using a frame with varying materials and insert shapes to fit individual users.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom masks are produced for individual patients using traditional methods, then manufacturing precision and adaptability to individual facial geometries are improved, but production time and cost increase significantly

Engineering Contradiction:

Improvemask fit precisionVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The mask frame is divided into multiple deformable zones that can independently adjust to different facial geometries. Each zone can be customized separately, allowing rapid adaptation to individual patient needs without requiring complete custom manufacturing of the entire mask.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mask incorporates deformable zones with varying material properties that allow dynamic adjustment and adaptation to the patient's facial contours. This enables a single mask design to accommodate multiple facial geometries through controlled deformation rather than requiring multiple fixed-size masks.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If traditional fixed-size masks are used, then manufacturing cost and complexity are reduced, but adaptability to different facial geometries deteriorates

Engineering Contradiction:

Improvefacial geometry adaptabilityVSAvoidmask structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Different zones of the mask frame are assigned different material properties and deformability characteristics. The deformable zones have specific material compositions that allow controlled deformation, while other portions maintain structural integrity. This localized differentiation enables adaptability without requiring the entire mask to be complex.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The mask frame utilizes composite materials with varying degrees of rigidity and flexibility in different regions. By combining materials with complementary properties, the mask achieves both structural stability and localized deformability, enabling adaptation to various facial geometries without excessive overall complexity.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If expensive custom mask production equipment is used, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecustom fit precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mask is pre-configured with deformable zones and removable inserts during manufacturing, allowing customization to occur at the point of use rather than requiring expensive post-production customization equipment. The preliminary preparation of the mask structure enables simple, low-cost adaptation to individual patients.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The design incorporates removable inserts that can be easily exchanged between patients. Rather than requiring expensive custom-manufactured masks for each patient, the same base mask can be rapidly reconfigured with different inserts, reducing the need for costly custom production while maintaining precision fit.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Provides a cost-effective, quickly customizable mask that fits a variety of facial geometries, improving patient adherence and therapy effectiveness without requiring expensive equipment or lengthy production times.

Implementation Method 1

a deformable zone (30) defined in the frame. Each deformable zone (30) may be formed from a first material, and the remainder of the frame may be formed from a second material different than the first material

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12515003B2Customizable mask and method of sizing

Publication Date: 2026.01.06 KONINKLIJKE PHILIPS NV

AI summary

A mask for use in providing a flow of a treatment gas to the airway of a user. The mask includes a frame and a conformable seal which is structured to sealingly engage about at least one of at least a portion of nose or mouth of the user. The frame includes a front face and a concave shaped rear face which faces the user when the mask is disposed on the user's face. The rear face defines a cavity which is structured to receive at least one of a portion of a nose and/or mouth of the user therein. The frame also includes a number of deformable zones, each deformable zone being structured to receive a removable insert. Each deformable zone is structured to adapt to at least one of a size or shape of the removable insert received therein.