Foldable Substrate Patient Interface for Cost Reduction
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Solution Overview
Problem
Current patient interface devices for pressure support systems are expensive and require extensive infrastructure for cleaning and reuse, posing challenges for hospitals and patients.
Innovation Solution
A patient interface device formed from a foldable flat substrate with seams that correspond to the perimeter of a nose, allowing for customizable fit and reduced material costs by using low-cost materials like paper or thin plastics, which can be easily folded and adjusted for a secure seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional patient interface devices are used, then reliable sealing and comfort are achieved, but high cost and complex cleaning infrastructure are required
Solution Approach 1:
The patent implements a disposable patient interface device made from a flat substrate that is folded to conform to the patient's face. The substrate includes a sealing surface with contours matching facial features (nose, cheeks, chin) and is designed for single-use or limited-use applications. This disposable approach eliminates the need for expensive traditional masks while removing complex cleaning infrastructure requirements, as each new device provides reliable sealing without requiring sterilization or maintenance.
Solution Approach 2:
The patent employs a thin, flexible substrate that can be folded into three-dimensional shape to create a patient interface device. The substrate material is engineered to be sufficiently flexible to conform to various facial geometries while maintaining structural integrity for reliable sealing. The thin-film construction reduces material costs compared to traditional rigid or semi-rigid mask components, while the folded configuration provides the necessary form factor for effective airway pressure delivery.
2Reliability
If traditional patient interface devices are used, then effective treatment is provided, but extensive cleaning and tracking infrastructure is needed
Solution Approach 1:
By making the patient interface device disposable, the patent eliminates the need for complex cleaning, sterilization, and tracking infrastructure that hospitals must maintain for reusable devices. Each disposable unit is pre-packaged and ready-to-use, reducing administrative burden and infrastructure requirements while ensuring treatment effectiveness through consistent, factory-controlled manufacturing quality.
3Ease of manufacture
If low-cost materials like paper or thin plastics are used, then manufacturing cost is reduced, but device strength and durability may be compromised
Solution Approach 1:
The patent utilizes thin plastic or paper-based substrate materials that are engineered to provide sufficient strength for their intended disposable application. The folded configuration creates structural rigidity where needed while maintaining flexibility for conforming to the face. The substrate is designed with appropriate thickness and material properties to withstand the pressures involved in airway pressure therapy without compromising device strength, while remaining cost-effective for single-use applications.
Solution Approach 2:
The substrate may incorporate composite material structures combining different layers or materials (such as coated paper or multi-layer plastic) to achieve the necessary strength-to-cost ratio. The composite construction provides adequate mechanical strength for device functionality while using cost-effective base materials, optimizing both manufacturing cost and device performance for disposable applications.
Data Source
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AI summary
An apparatus including a patient interface device formed from a flat substrate that is folded, wherein the patient interface device includes a plurality of seams where sections of the substrate are joined together, and wherein one or more of the plurality of seams form a shape that corresponds to a perimeter of a bottom side of a nose from a first alare corner of the nose to a tip of the nose to a second alare corner of the nose.