Gradient CPAP Mask for Comfort and Seal
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Solution Overview
Problem
Current CPAP masks often cause discomfort and have high leak rates due to inadequate sealing, leading to ineffective treatment for obstructive sleep apnea and other sleep disorders, as well as issues in other medical and non-medical applications where differential pressure is involved.
Innovation Solution
The development of facial masks featuring material gradients, fabricated using 3D printing, which transition seamlessly from softer to harder materials for improved comfort and fit, reducing leak rates and enhancing pressure distribution without visible boundaries, allowing for customized production directly from facial scans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mask is made with uniform hard material to provide structure and shape, then structural integrity is improved, but comfort and seal quality deteriorate due to discomfort and high leak rates
Solution Approach 1:
The mask incorporates a material gradient where the distal portion (contacting skin) is softer and more compliant for comfort and sealing, while the proximal portion maintains hardness for structural support. This local differentiation of material properties resolves the contradiction between structural integrity and seal quality.
Solution Approach 2:
The patent changes the material parameter (hardness/softness) along the length of the mask foot, creating a gradient transition from hard proximal material to soft distal material. This parameter change enables the mask to simultaneously achieve structural integrity where needed and compliance for sealing where it contacts the skin.
2Ease of operation
If a mask is made with uniform soft material to improve comfort, then comfort is improved, but structural support and shape maintenance deteriorate
Solution Approach 1:
The mask incorporates a material gradient where the distal portion (contacting skin) is softer and more compliant for comfort and sealing, while the proximal portion maintains hardness for structural support. This local differentiation of material properties resolves the contradiction between structural integrity and seal quality.
Solution Approach 2:
The patent changes the material parameter (hardness/softness) along the length of the mask foot, creating a gradient transition from hard proximal material to soft distal material. This parameter change enables the mask to simultaneously achieve structural integrity where needed and compliance for sealing where it contacts the skin.
3Ease of manufacture
If a mask uses abrupt material transition to combine soft and hard materials, then manufacturing simplicity is improved, but comfort and seal quality deteriorate due to visible boundaries and pressure distribution issues
Solution Approach 1:
The patent implements a gradual material transition where the material composition changes progressively along the mask foot rather than abruptly. This creates a seamless gradient that eliminates visible boundaries and improves pressure distribution, enhancing seal quality while maintaining manufacturability through controlled material deposition.
Solution Approach 2:
The mask utilizes a composite structure with multiple materials blended in a gradient fashion. The composite material system transitions from hard proximal material to soft distal material through intermediate compositions, achieving both functional requirements and aesthetic continuity.
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 use of material gradients in CPAP masks reduces discomfort, improves sealing, decreases leak rates, and enhances treatment effectiveness for sleep apnea, while also benefiting other medical and non-medical applications by providing increased comfort and better fit through customized pressure distribution.
Implementation Method 1
fabricated using 3D printing
Implementation Method 2
a foam layer covering at least a portion of the second material
Data Source
AI summary
Masks for various uses and methods for manufacture thereof, including masks for use in continuous positive air pressure (CPAP) therapies. An example includes a mask having a first, relatively softer material for contact with the face of the user, and a second, relatively harder or more structural material used away from the face of the user, with a gradient therebetween. The mask can be produced by additive manufacturing to avoid a discernible boundary between the first and second materials. The mask may include a foam element, which can be removable for replacement in some examples, for contacting the patient's skin.