Knitted Headgear Strap Structure for Stable CPAP Mask Sealing

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Solution Overview

Problem

Existing patient interfaces for respiratory therapies, such as CPAP, are often uncomfortable, difficult to use, and poorly fitting, leading to reduced patient compliance and ineffective treatment of respiratory disorders.

Innovation Solution

A patient interface with a positioning and stabilizing structure comprising an integrally formed knitted strap, featuring different mechanical properties and ventilation portions, designed to maintain a seal and provide comfort during therapy, using flat knitting techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-piece headgear strap is used, then device complexity is reduced, but positioning precision and stability deteriorate

Engineering Contradiction:

Improveheadgear strap constructionVSAvoidpositioning precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The headgear strap incorporates different knit structures in different areas: a first knit structure in the first area, a second mesh knit structure in the second area forming ventilation areas, and a pique knit structure in the third area. This local differentiation allows each area to have optimized properties for its specific function while maintaining a single-piece construction.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If a single-piece headgear strap is used, then ease of manufacture is improved, but stability deteriorates

Engineering Contradiction:

Improveheadgear strap constructionVSAvoidpositioning stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The headgear strap is formed from a single piece of knitted material that integrates multiple knit structures (first knit structure, second mesh knit structure, and pique knit structure) into one composite construction, combining the advantages of different material properties in a unified element.

Inventive Principle:

Principle #40Composite materials

3Reliability

If traditional headgear straps are used, then positioning is achieved, but patient comfort deteriorates due to lack of ventilation

Engineering Contradiction:

Improvepositioning reliabilityVSAvoidpatient discomfort

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The second mesh knit structure forms ventilation areas with increased flexibility that allow air flow through the headgear strap, providing breathable zones that reduce patient discomfort while maintaining positioning function.

Inventive Principle:

Principle #31Porous materials

4Ease of manufacture

If uniform knit structure is used throughout headgear strap, then manufacturing is simplified, but functional versatility deteriorates

Engineering Contradiction:

Improveheadgear strap constructionVSAvoidfunctional adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4374899B1Positioning and stabilizing structure for a patient interface

Publication Date: 2026.05.13 RESMED ASIA PTE LTD

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AI summary

The present invention relates to a patient interface for sealed delivery of a flow of air comprising: a plenum chamber including a plenum chamber inlet port; a seal-forming structure having a hole formed therein such that the flow of air at said therapeutic pressure is delivered to at least an entrance to the patient's nares; a positioning and stabilising structure constructed and arranged so that at least a portion overlies a region of the patient's head superior to an otobasion superior of the patient's head in use, wherein the positioning and stabilizing structure comprises a one-piece knitted headgear strap of a single piece of material; wherein the knitted headgear strap includes at least one first area having a first knit structure; at least one second area having a second mesh knit structure forming at least one ventilation area having increased flexibility as compared to the first area; and at least one third area having a pique knit structure.