One-Piece Mask System Headgear and Cushion Integration
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Solution Overview
Problem
Existing mask systems for treating Sleep Disordered Breathing (SDB) often face challenges in comfort, fit, and manufacturing cost, which can affect therapy efficacy and patient compliance.
Innovation Solution
A mask system with a headgear and cushion module featuring a one-piece construction with an outer fabric layer and an inner cushioning layer, providing a robust seal and adjustable fit, while reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional multi-component mask systems are used, then manufacturing flexibility and customization are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the headgear and cushion into a single integrated one-piece construction, eliminating the need for separate components that would normally be assembled together. This merging reduces device complexity while maintaining the ability to customize through fabric selection and design variations.
Solution Approach 2:
The one-piece construction serves multiple functions simultaneously: it provides structural support as headgear, cushioning as the sealing surface, and integration for simplified manufacturing. This multi-functionality reduces the number of separate components needed while maintaining customization options.
2Ease of manufacture
If traditional multi-component mask systems are used, then manufacturing flexibility is improved, but manufacturing cost and time increase
Solution Approach 1:
By merging the headgear and cushion into one-piece construction, the manufacturing process is simplified from assembling multiple components to producing a single integrated piece, reducing manufacturing time and operational complexity.
Solution Approach 2:
The one-piece construction allows all structural and cushioning features to be pre-formed during a single manufacturing process, eliminating the need for subsequent assembly operations and reducing overall manufacturing time.
3Adaptability or versatility
If traditional mask systems with separate components are used, then adjustability is improved, but device complexity and fit time increase
Solution Approach 1:
The integration of headgear and cushion into one piece eliminates the need to assemble multiple components during fitting, reducing fit time while maintaining adjustability through the design of the integrated structure itself.
Data Source
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AI summary
A mask system (10) for treatment of Sleep Disordered Breathing with Continuous Positive Airway Pressure or Non-Invasive Positive Pressure Ventilation, comprising a cushion region (30,230) adapted to define a breathing chamber and adapted to form a seal with a patient's face, wherein the cushion region comprises a fabric layer (25) positioned about or around the patient's airways, a central portion (250) adjacent the patient's airways, the central portion arranged to define the breathing chamber; and at least one headgear strap (242,244) including fabric, the at least one headgear strap adapted to maintain the cushion region in position on the patient's face, wherein the at least one headgear strap contains an air delivery tube within the fabric.