Fiber-Based Seal Forming Portion for Patient Interface Comfort
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Solution Overview
Problem
Existing respiratory disorder treatment devices, such as those for Obstructive Sleep Apnea, Cheyne-Stokes Respiration, Obesity Hyperventilation Syndrome, Chronic Obstructive Pulmonary Disease, and Neuromuscular Diseases, face challenges with uncomfortable and poorly fitting patient interfaces that lead to leaks and discomfort, affecting the efficacy of treatment.
Innovation Solution
A patient interface with a seal-forming portion comprising a base surface and a plurality of fibers extending away from it, providing improved tactile experience, sweat dissipation, and self-positioning, which can be manufactured using a method involving a resilient material and adhesive, allowing for adjustable resilience and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional patient interface seal-forming portion is used, then the device structure is simple, but the fit is poor and leaks occur
Solution Approach 1:
The seal-forming portion incorporates fibers with varying properties (length, density, material composition) in different regions to optimize local sealing performance. The fibers are distributed non-uniformly with higher density in critical sealing zones, providing enhanced adaptability to facial contours while maintaining overall structural simplicity.
Solution Approach 2:
The seal-forming portion uses a composite structure combining fibers with different material properties (e.g., hydrophilic and hydrophobic fibers, fibers of varying elasticity) to achieve both conformability and sealing reliability. This composite approach allows the seal to adapt to various skin types and facial geometries without significantly increasing device complexity.
2Ease of operation
If the seal-forming portion is made more compliant for comfort, then comfort is improved, but structural stability deteriorates
Solution Approach 1:
The seal-forming portion employs a flexible fiber-based structure that conforms to the facial surface while maintaining structural integrity. The fibers act as a flexible matrix that provides both comfort through adaptability and stability through collective structural support, avoiding the need for rigid components.
Solution Approach 2:
The seal-forming portion is divided into multiple fiber elements rather than a single continuous structure. This segmentation allows each fiber to independently deform and adapt to facial contours for comfort, while the collective arrangement of numerous fibers maintains overall structural stability and prevents excessive deformation.
3Manufacturing precision
If adhesive is used to fix fibers, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
An adhesive layer serves as an intermediary substance between the substrate and fibers, enabling precise fiber positioning without requiring complex mechanical fixing mechanisms. The adhesive provides controlled bonding that secures fibers in desired patterns while allowing for relatively simple manufacturing processes such as dip-coating or spray-application.
Solution Approach 2:
The adhesive properties (viscosity, curing time, bonding strength) are optimized to achieve precise fiber fixation during manufacturing. By controlling adhesive parameters such as application thickness and curing conditions, the process achieves high manufacturing precision while remaining relatively simple and scalable for production.
Data Source
AI summary
A patient interface includes a seal forming portion, a pad, and a cushion. The seal forming portion may have a base surface and a plurality of fibers fixed to and extending away from the base surface for contacting a patient's skin. The cushion may have at least along a portion of the circumference a first structure having an elongate section joined with at least one end section oriented substantially perpendicular or at an angle to the elongate section. A first end A of the elongate section may be connected or connectable to a frame member. The end section may be provided at an opposing second end B of the elongate section. The pad may have a resilient foam material layer with the seal forming portion. The pad may be adapted to be connected to the cushion.