Respiratory Mask Cushion with Segmented Gas-Filled Chambers

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Solution Overview

Problem

Respiratory treatment masks often face challenges in providing a comfortable and effective seal against leaks, especially when delivering therapeutic pressures for conditions like obstructive sleep apnea, due to inadequate design and material properties.

Innovation Solution

A mask cushion design featuring a flexible inner cushion component and an outer barrier or membrane forming a chamber, which can include gases or fluids, to conform to the patient's face and maintain a seal, using materials like soft foam, elastomeric structures, and porous fabrics, with optional internal barriers to prevent fluid permeation and adjust comfort and sealing efficacy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mask is designed to deliver therapeutic pressures above atmospheric pressure, then treatment effectiveness is improved, but comfort and sealing effectiveness deteriorate due to inadequate design

Engineering Contradiction:

Improvetreatment effectivenessVSAvoidcomfort and sealing effectiveness

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The cushion is divided into multiple chambers separated by partitions, with each chamber containing adjustable filling material. This segmentation allows different regions of the cushion to be independently adjusted for optimal sealing and comfort while maintaining therapeutic pressure delivery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cushion incorporates adjustable filling material that can be modified to change the cushion's shape and pressure distribution dynamically. This allows the mask to adapt to different facial contours and maintain effective sealing while delivering therapeutic pressures.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If a mask cushion uses traditional materials and design, then manufacturing simplicity is maintained, but sealing effectiveness and comfort deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsealing effectiveness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cushion utilizes porous filling material that can be injected into the cushion chambers through injection ports. This porous material provides excellent conformability to facial contours for effective sealing while maintaining a relatively simple manufacturing process involving material injection and curing.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The cushion combines multiple materials including the cushion body structure, porous filling material, and barrier membranes to achieve both effective sealing and comfort. This composite approach maintains manufacturing simplicity by using established material combinations while significantly improving sealing effectiveness.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If a mask cushion uses a single-chamber design, then device complexity is reduced, but adaptability to facial contours and sealing effectiveness deteriorate

Engineering Contradiction:

Improvecushion structure complexityVSAvoidadaptability to facial contours

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each chamber can be independently filled with varying amounts and types of filling material to create local variations in cushion properties. This allows different regions of the cushion to be optimized for specific facial contours and anatomical features, enhancing overall adaptability.

Inventive Principle:

Principle #3Local quality

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 cushion provides a comfortable and effective seal, reducing leaks and enhancing treatment delivery by conforming to facial contours and accommodating micro-topography, while maintaining the inner chamber substance, thus improving the overall performance of respiratory treatment masks.

Implementation Method 1

The cushion may include an inner cushion component and an outer barrier or membrane, that may optionally be a flexible chamber, to form a chamber

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The inner cushion component may comprise a porous structure formed of an elastomeric material

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 3

The chamber may include a gas or a fluid therein. The gas may optionally be air

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS20230073790A1Cushion assembly for a respiratory mask

Publication Date: 2023.03.09 RESMED PTY LTD

AI summary

A mask cushion or a mask assembly therewith provides a comfortable and effective seal for provision of a gas therapy by a respiratory treatment apparatus. The mask cushion may be integrated with or coupled to a mask frame. The mask cushion typically includes an inner cushion component. The mask cushion also includes a patient facial-contact side portion with a chamber and a barrier to form the chamber that may be flexible. The chamber may serve as an outer layer with respect to the inner cushion component. The chamber may be partially or completely filled with a gas, fluid or gel. The inner cushion may be formed with a soft flexible material such as an elastomer or foam, etc. The barrier may be a membrane and may also be soft flexible material.