Dimpled Flap Cushion for CPAP Mask Seal
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Solution Overview
Problem
Current patient interface devices for treating sleep disordered breathing, such as CPAP masks, face challenges in providing a comfortable seal due to the trade-off between structural support and flexibility, with thin flaps straining easily and thick flaps causing discomfort and red marks.
Innovation Solution
The introduction of a cushion member with a multi-dimensional array of dimples in the sealing flap, which provides both stretch and structure, allowing for improved sealing and comfort by distributing forces more effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thin sealing flaps are used, then flexibility and comfort are improved, but structural support deteriorates causing the flap to strain easily
Solution Approach 1:
The sealing flap is designed with non-uniform thickness, being thinner at the free end for flexibility and comfort, and thicker at the base for structural support. This local variation in thickness allows different regions of the same component to have different mechanical properties, resolving the contradiction between flexibility and structural support.
Solution Approach 2:
The sealing flap transitions from a two-dimensional planar structure to a three-dimensional contoured structure with varying thickness. This dimensional change allows the flap to have both flexible regions (thin areas) and supportive regions (thick areas), enabling it to simultaneously achieve comfort and structural integrity.
2Strength
If thick sealing flaps are used, then structural support is improved, but comfort deteriorates causing red marks and discomfort
Solution Approach 1:
The sealing flap employs local quality variation through non-uniform thickness distribution, being thicker at the base for structural support and thinner at the free end for comfort. This prevents the entire flap from being thick, thereby avoiding the discomfort and red marks associated with thick flaps while maintaining necessary structural support.
Solution Approach 2:
The thickness parameter of the sealing flap is changed across different locations rather than being uniform. This parameter variation allows the flap to provide structural support where needed (thicker base) while minimizing discomfort in contact areas (thinner free end), resolving the contradiction between strength and comfort.
3Ease of manufacture
If uniform thickness sealing flaps are used, then manufacturing is simplified, but performance deteriorates due to inability to provide both stretch and structure
Solution Approach 1:
The sealing flap uses local quality variation with non-uniform thickness to achieve different functions in different regions. The thinner free end provides stretch and conformability for sealing, while the thicker base provides structural support. This localized differentiation improves sealing performance without requiring complex multi-component assemblies, maintaining manufacturing feasibility.
Solution Approach 2:
The sealing flap can be constructed using composite materials or multi-layer structures that combine materials with different mechanical properties. This allows the single component to exhibit both flexible and supportive characteristics, achieving reliable sealing performance while maintaining manufacturing simplicity through a unified component design.
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 dimpled design enhances the sealing capability of the cushion member, reducing strain and discomfort, while maintaining structural integrity, thus providing a more effective and comfortable solution for delivering breathing gas during sleep therapy.
Implementation Method 1
The dimpled design enhances the sealing capability of the cushion member, reducing strain and discomfort, while maintaining structural integrity
Data Source
AI summary
A cushion member for use in a patient interface device for delivering a flow of breathing gas to an airway of a patient includes a plurality of dimples defined in a portion of the cushion member.