Respiratory Mask Forehead Coupler for Leak Reduction
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Solution Overview
Problem
Existing headgear connection assemblies for respiratory masks are bulky, difficult to adjust, and lack markers for indicating adjustment amounts, leading to poor user compliance and potential leaks due to uneven adjustment.
Innovation Solution
A respiratory mask system with a forehead coupler that includes a pair of strap connectors connected by a flexible linking member, allowing for an adjustable closed loop around the patient's head, and a frame connector that removably couples to the coupler connection, providing independent movement and conforming to the forehead shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional buckle connection assembly is used, then the headgear can be secured to the mask, but the buckle becomes bulky and uncomfortable on the patient's head
Solution Approach 1:
The connection assembly is divided into separate components: a frame connector with a tongue that inserts into a coupler connection with a groove. This segmentation eliminates the need for a bulky traditional buckle while maintaining secure connection through the tongue-groove interface, reducing discomfort on the patient's head.
Solution Approach 2:
The traditional buckle is completely removed from the design. Instead, a simplified frame connector with a tongue element is used to engage with the coupler connection, extracting the harmful bulky buckle while preserving the essential connection function.
2Ease of operation
If traditional headgear adjustment mechanisms are used, then the crown strap can be adjusted, but the adjustment is difficult and ambiguous without markers
Solution Approach 1:
Visual markers or color-coded indicators are incorporated into the adjustment mechanism to provide clear feedback on the amount of adjustment made. This allows users to easily see and track adjustments without ambiguity, improving ease of operation while preventing information loss about the adjustment state.
3Ease of manufacture
If the headgear is disconnected for cleaning, then the mask can be cleaned, but the headgear requires time-consuming trial and error to refit
Solution Approach 1:
The headgear connection is designed with self-aligning features and clear engagement indicators that allow for quick and accurate reconnection after cleaning. The preliminary design of the tongue-groove interface with visual markers enables users to rapidly refit the headgear without trial and error, significantly reducing refitting time while maintaining cleaning accessibility.
4Ease of operation
If the crown strap adjustment is not evenly distributed, then the headgear can be assembled, but it sits lopsided on the patient's head causing leaks
Solution Approach 1:
The connection design incorporates asymmetric features that guide proper alignment and distribution of strap tension. The tongue-groove interface with visual markers ensures that adjustments are evenly distributed across the headgear, preventing lopsided positioning and maintaining reliable sealing while keeping assembly simple.
Data Source
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AI summary
A frame (1301) for a respiratory mask system, wherein the respiratory mask system comprises the frame (1301), a headgear (160) having first and second forehead straps (163), and a forehead coupler (1300), the forehead coupler (1300) configured to connect the first and second forehead straps (163) together in a closed loop and removably connect the first and second forehead straps (163) to the frame (1301), the forehead coupler (1300) comprising a pair of lateral strap connectors (1302) and a frame connector (1303) configured to link the strap connectors (1302) together, the frame connector (1303) comprising a crossbar (1311) and a rib slot (1312), the frame (1301) comprising a forehead support comprising a coupler connection (1304), the coupler connection (1304) comprising: a hook portion comprising: a shank (1317) formed by the forehead support of the frame (1301), a bend (1318) connected to the shank (1317), a return arm (1319) connected to the bend (1318), a throat portion (1320) formed between the shank (1317) and the return arm (1319); and a rib (1323) extending into the throat portion (1320) from the shank (1317) toward the return arm (1319).