Gel-Filled Flexible Mask Structure for Facial Contour Adaptation
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Solution Overview
Problem
Respiratory masks for treating sleep disordered breathing often compromise comfort due to inadequate cushioning and sealing, leading to discomfort and reduced therapy efficacy, and existing testing methods struggle to accurately evaluate mask performance across varying face shapes and sizes.
Innovation Solution
A respiratory mask with a flexible structure featuring chambers filled with soft materials like gel, designed to distribute force evenly and adjust to different facial contours, combined with a method for testing mask performance using force-deflection curves to optimize comfort and sealing effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid or semi-rigid cushion structures are used, then manufacturing precision and structural stability are improved, but comfort and adaptability to different facial contours deteriorate
Solution Approach 1:
The cushion uses a flexible membrane structure filled with gel material, replacing traditional rigid or semi-rigid cushion structures. This flexible shell approach allows the cushion to conform to different facial contours while maintaining structural integrity through the gel filling, directly resolving the contradiction between structural stability and adaptability.
Solution Approach 2:
The invention combines a flexible membrane material with gel filling material to create a composite cushion structure. The membrane provides structural framework while the gel provides adaptability and comfort, achieving both manufacturing precision and facial contour adaptability simultaneously.
2Ease of operation
If softer cushioning materials are used, then comfort is improved, but sealing effectiveness deteriorates
Solution Approach 1:
The composite structure of flexible membrane plus gel filling creates a material system that exhibits both softness for comfort and sufficient sealing capability. The gel material's viscoelastic properties allow it to deform comfortably while maintaining contact pressure for effective sealing.
Solution Approach 2:
The gel filling material's unique rheological parameters (viscoelasticity, yield stress) enable it to provide both comfort through soft deformation and sealing through sustained contact pressure, resolving the contradiction between comfort and sealing effectiveness.
3Adaptability or versatility
If gel filling material is used, then comfort and adaptability are improved, but device complexity increases
Solution Approach 1:
The gel filling material is nested within the flexible membrane structure, creating a simplified integrated cushion assembly. This nesting approach encapsulates the complex gel material within a simple membrane shell, reducing overall device complexity while maintaining comfort and adaptability benefits.
4Reliability
If headgear tension is increased, then sealing is improved, but comfort deteriorates due to increased force on facial features
Solution Approach 1:
The flexible membrane with gel filling acts as a force-distributing interface that reduces the impact of headgear tension on facial features. The gel material's compliance allows it to deform under tension, distributing forces more evenly and reducing localized pressure points, thus maintaining sealing while improving comfort.
Solution Approach 2:
The viscoelastic parameters of the gel material allow it to dissipate and redistribute mechanical forces from headgear tension, reducing the peak forces transmitted to facial features while maintaining sufficient contact pressure for sealing effectiveness.
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 mask provides improved comfort and reduced sensitivity to headgear tension, accommodating a range of facial shapes and sizes while maintaining effective sealing, and the testing method allows for precise evaluation of mask performance, enhancing user compliance and therapy outcomes.
Implementation Method 1
A first aspect of the present technology is a comfortable cushion for use as part of a respiratory mask assembly... The cushion is constructed to have certain performance characteristics that enhance comfort and or simply adjustment while maintaining seal... provide improved desensitivity to adjustments in headgear tension
Implementation Method 2
A respiratory mask with a flexible structure featuring chambers filled with soft materials like gel, designed to distribute force evenly and adjust to different facial contours
Data Source
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AI summary
A respiratory mask (10) includes a flexible structure (20) adapted to engage a patient's face. The flexible structure includes a chamber filled with at least a first gel. The flexible structure is adapted to provide a very comfortable fit with the wearer, while providing a good seal and even distribution of forces. Properties of the mask, e.g., the seal, may be measured with a testing machine having an indenter that allows measurement of applied force as a function of indentation. The flexible structure includes a lip/chin region, nasal bridge region, and cheek regions that may be tested, e.g., in terms of hardness and/or viscoelastic behaviour.