Respiratory Mask Seal Using Super-Elastomeric Material
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Solution Overview
Problem
Conventional respiratory masks face challenges in providing a comfortable and effective seal against the patient's face for extended periods, while minimizing gas leakage and accommodating various facial structures and sizes.
Innovation Solution
A respiratory mask seal made from a unitary piece of super-elastomeric material with a thermoplastic gel, featuring a seal support and conduit coupling member, which allows for a secure fit and reduced leakage through its elongation properties and smooth, silky touch, eliminating the need for bulky or heavy gel cushions and flap-like features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seals use soft gel material or bubble-type configurations to create a mask-to-face seal, then gas leakage is minimized, but the seal becomes bulky, heavy, or uncomfortable for extended wear
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional soft gel materials to a thermoplastic elastomer material with specific physical properties (Shore 00 hardness of 20-30, 300% modulus of 10-15 PSI, elongation of 1000% or greater). This material parameter change achieves effective sealing without the bulk and weight of traditional gel cushions while maintaining comfort for extended wear.
Solution Approach 2:
The patent uses composite materials by combining thermoplastic elastomer properties with gel-like characteristics. The material exhibits both the structural integrity needed for a reliable seal and the softness required for patient comfort, eliminating the need for bulky gel cushions while maintaining seal effectiveness.
2Reliability
If conventional seals use multiple flaps or complex configurations to accommodate different facial structures, then seal effectiveness improves, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a simplified seal structure that can accommodate various facial structures and sizes without requiring multiple flaps or complex configurations. The thermoplastic elastomer material's high elongation (1000% or greater) allows a single seal design to adapt to different patient anatomies, eliminating the need for complex multi-flap structures.
Solution Approach 2:
The patent uses local quality by providing structural reinforcement only where needed - specifically at the sidewalls and connection points - while maintaining material softness and flexibility at the patient-contacting surfaces. This localized structural differentiation achieves reliable sealing without overall structural complexity.
3Ease of operation
If seal material is made softer to improve patient comfort, then ease of operation improves, but seal reliability may deteriorate due to insufficient structural support
Solution Approach 1:
The patent uses composite materials to reconcile the contradiction between softness and structural support. The thermoplastic elastomer combines gel-like softness (Shore 00 hardness of 20-30) with elastic structural integrity (elongation of 1000% or greater), providing both patient comfort and reliable sealing without requiring hard or bulky structures.
Solution Approach 2:
The patent applies parameter changes by optimizing the material's physical properties - specifically selecting a Shore 00 hardness of 20-30 and 300% modulus of 10-15 PSI - to achieve the optimal balance between softness for comfort and structural integrity for reliable sealing.
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 solution provides a comfortable, leak-resistant seal that fits a wide range of facial structures, enhancing patient compliance with pressure support therapy by using a thermoplastic gel material with specific hardness, modulus, and tear strength properties, allowing for complex contour designs and economic manufacturing processes.
Implementation Method 1
an elastomeric material having an elongation in a range of 1000% or greater
Data Source
AI summary
A seal and a mask using a seal that includes a first end portion adapted to be coupled to a seal support, a second end portion adapted for sealing engagement with a face of a user, and a sidewall extending between the first end portion and the second end portion. The first end portion, second end portion, sidewall, or any combination thereof is formed from an elastomeric material having an elongation of at least 1000%. The seal preferably formed from a unitary piece of elastomeric material.