Foamed-on Patient Interface Cushion for Seamless Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing patient interfaces, such as breathing masks, face challenges with complex manufacturing processes, durability, comfort, and sealing effectiveness due to the need for multiple parts and assembly, leading to increased costs and limitations in design and hygiene.
Innovation Solution
A patient interface component comprising a first part made of a hard material and a second part made of a soft, foamed material, where the second part is foamed onto the first part, allowing for efficient and effective production without the need for complex assembly or additional materials, and providing improved comfort and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are used for patient interface components, then design flexibility and functionality are improved, but manufacturing complexity and assembly requirements increase
Solution Approach 1:
The patent combines multiple separate components (cushion, sealing lip, support structure) into a single integrated patient interface component manufactured as one piece. This merging eliminates the need for multiple parts and complex assembly processes while maintaining all necessary functions through careful design of the monolithic structure.
Solution Approach 2:
The single integrated component performs multiple functions simultaneously: providing patient comfort through the cushion, creating seals through integrated sealing lips, and providing structural support. This multi-functionality in a single part reduces manufacturing complexity while maintaining design flexibility.
2Manufacturing precision
If manual assembly steps are used for manufacturing patient interfaces, then customization and quality control are improved, but productivity and cost-effectiveness decrease
Solution Approach 1:
The patent replaces manual assembly operations with automated injection molding processes. The monolithic design allows the entire component to be manufactured in one automated molding cycle, eliminating manual assembly steps while maintaining high quality control through consistent automated manufacturing processes.
Solution Approach 2:
The design incorporates all necessary features (sealing lips, cushions, connection structures) directly into the molded part during the initial manufacturing process. This preliminary formation of all features eliminates subsequent assembly operations and enables direct automation of the manufacturing process.
3Strength
If hard materials are used for structural components, then durability and strength are improved, but comfort and sealing effectiveness deteriorate
Solution Approach 1:
The patent uses a single material with optimized properties that combines the strength needed for structural integrity with the softness required for patient comfort and effective sealing. The material selection and design ensure that even hard-to-soft transitions are smooth, preventing pressure marks while maintaining durability.
Solution Approach 2:
The design optimizes material distribution and structural geometry to provide local variations in hardness and compliance. Areas contacting the patient's face are designed with appropriate compliance for comfort and sealing, while other areas maintain structural strength, all within the monolithic component.
4Strength
If additional connection structures and materials are used to assemble parts, then structural integrity is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent integrates connection structures directly into the monolithic component during molding, eliminating the need for separate connection elements and additional materials. The single-piece construction inherently provides structural integrity through continuous material without requiring additional fasteners or joining materials.
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 solution enables the production of patient interfaces with enhanced comfort, reduced pressure marks, and improved hygiene, while allowing for individualization and efficient automated manufacturing, resulting in a more durable and cost-effective product.
Implementation Method 1
The second part is made of a soft, foamed material, wherein the second part is foamed onto the first part
Data Source
AI summary
Component of a patient interface, particularly a cushion, comprising a first part and a second part, wherein the second part is made of a foamed material which is foamed-on the first part. A Method and tool for manufacturing a component of a patient interface, particularly a cushion, comprising the steps molding a first part of the component and foaming a second part on the first part.