Dual-Material Cushion Member for Sleep Apnea Seal

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Solution Overview

Problem

Existing patient interface devices suffer from leaks between the sealing cushion and the patient's face during sleep apnea therapy, leading to discomfort and compromised therapy effectiveness.

Innovation Solution

A dual-material cushion member with different coefficients of thermal expansion, which changes shape in response to environmental changes such as temperature and humidity, enhancing the seal by becoming more convex and reducing the contact area with the face, thereby minimizing leaks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sealing cushion is made with a large contact area to improve sealing, then the seal quality improves, but the comfort of the patient deteriorates due to excessive pressure on the face

Engineering Contradiction:

Improveseal qualityVSAvoidpatient discomfort

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The cushion member utilizes changes in environmental parameters (temperature and humidity) to automatically adjust its shape. When the patient's breath warms and humidifies the air inside the cushion, the materials expand at different rates, causing the cushion to become more convex and reduce contact area with the face, thereby maintaining seal quality while improving comfort

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention employs materials with different coefficients of thermal expansion that respond to temperature changes from the patient's breath. The first material expands more than the second material when heated, causing the cushion to deform into a more convex shape that reduces face contact area while maintaining the seal

Inventive Principle:

Principle #37Thermal expansion

Solution Approach 3:

The cushion member responds to phase changes in the microenvironment (temperature and humidity changes from patient's breath) that trigger material expansion and shape changes, allowing the cushion to adapt its contact area dynamically without manual intervention

Inventive Principle:

Principle #36Phase transitions

2Reliability

If the cushion is made rigid to maintain seal shape, then sealing effectiveness improves, but adaptability to different patients and conditions deteriorates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidadaptability to different patients

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The cushion member transitions from a static structure to a dynamic one that automatically adjusts its shape in response to environmental changes. The combination of materials with different thermal expansion coefficients allows the cushion to become more convex when warmed by the patient's breath, adapting the seal to the specific patient's face contours and breathing conditions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cushion's physical parameters (shape and contact area) change in response to changes in environmental parameters (temperature and humidity). This allows the same cushion design to adapt to different patients and conditions without requiring multiple custom-fitted cushions

Inventive Principle:

Principle #35Parameter changes

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 dual-material cushion member significantly reduces leaks, improving patient comfort and the quality of pressure support therapy by maintaining a better seal during therapy.

Implementation Method 1

A cushion member for a patient interface device, in which a support portion includes a first material and a number of second portions made of a second material different than the first material, each having a coefficient of thermal expansion different than, and less than, the coefficient of thermal expansion of the first material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

Methodology Applied

Scientific EffectHumidity-induced deformation:

Data Source

PatentEP3551268B1Cushion member and method of manufacturing same

Publication Date: 2024.10.02 KONINKLIJKE PHILIPS NV

Figure 1~3
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Figure 7~8

AI summary

A cushion member (2) is for a patient interface device. The cushion member includes a body portion (4) having a first end (6) and a second end (8) disposed opposite the first end, the body portion defining a passage (5) therethrough, and a support portion (10) extending from the second end into the passage. The support portion includes a first portion (12) and a second portion (14)disposed on or in the first portion. The support portion is movable from a first configuration to a second configuration responsive to a change in environment.