Customized Mask Rigid Support Member

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional non-invasive ventilation masks are challenging to manufacture customly due to time-consuming and expensive molding techniques, leading to inaccurate fits and discomfort for patients.

Innovation Solution

A method involving generating surface geometry data of a patient's face, creating modified cushion geometry data to shape a rigid support member with a unitary material, and coupling a sealing flap to minimize pressure on sensitive areas, using three-dimensional scanning and printing for accurate and durable mask production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom molding techniques are used to manufacture customized masks, then manufacturing precision is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improvemask fit accuracyVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent changes the material parameter from soft to rigid, which fundamentally alters the manufacturing approach. Rigid support members can be manufactured using rapid prototyping techniques that are faster and more cost-effective than traditional custom molding, while still achieving accurate facial conformity through digital scanning and automated fabrication processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical custom molding process with a digital workflow involving 3D scanning, computer-aided design, and rapid prototyping. This substitution of mechanical manufacturing with digital fabrication methods significantly reduces manufacturing time and cost while maintaining or improving precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If soft materials are used for both support feature and sealing feature, then ease of manufacture is improved, but manufacturing precision and durability worsen

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcustomization accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent divides the mask into two distinct segments: a rigid support member and a soft sealing flap. This segmentation allows each component to be optimized for its specific function - the rigid support for structural accuracy and the soft flap for sealing - while being manufactured using different, more suitable techniques

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite construction by combining rigid material (for the support member) with soft material (for the sealing flap). This composite approach leverages the advantages of both material types, achieving both manufacturing precision and sealing effectiveness

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If the sealing feature is made very thin to conform to the face, then adaptability is improved, but strength and durability worsen

Engineering Contradiction:

Improvefacial conformityVSAvoidintrinsic strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent separates the conforming function from the sealing function. The rigid support member handles facial conformity through its customizable geometry, while the soft sealing flap provides the sealing action, eliminating the need for the sealing feature to be both thin and strong simultaneously

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the material parameter of the support structure from soft to rigid, which dramatically increases intrinsic strength while maintaining facial conformity through digital design. This parameter change allows the support feature to provide both adaptability and strength

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If traditional soft materials are used for the support feature, then ease of manufacture is improved, but reliability and comfort worsen due to inaccurate customization

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmask fit reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces traditional soft material molding with rigid material rapid prototyping. This substitution enables more reliable customization through digital scanning and automated fabrication, eliminating the inaccuracies associated with manual or semi-manual molding processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the material state from soft to rigid, which fundamentally improves reliability by enabling precise digital manufacturing. The rigid material maintains its manufactured geometry accurately, ensuring consistent and reliable fit across multiple units of the same design

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11058838B2Customized mask with rigid support

Publication Date: 2021.07.13 KONINKLIJKE PHILIPS NV

AI summary

A customized mask is manufactured by the process of: generating surface geometry data of a face of a patient, the surface geometry data corresponding to and representing a surface geometry of the face of the patient; generating original cushion geometry data using the surface geometry data; generating modified cushion geometry data using the original cushion geometry data; producing a rigid support member using the modified cushion geometry data such that it is shaped according to the modified cushion geometry data, the support member being made of a unitary material; and coupling a sealing flap to the support member, the sealing flap being structured to engage the face of the patient.