Modular CPAP Mask Assembly for Stable Nares and Mouth Sealing

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Solution Overview

Problem

Existing CPAP mask systems for treating sleep disordered breathing conditions are often uncomfortable, require multiple purchases due to lack of versatility, and can be dislodged by bed clothing, leading to poor patient compliance and high costs.

Innovation Solution

A modular or integrated mask system with a nares and mouth portion that can be used separately or together, featuring flexible components and stabilizing structures, allowing for interchangeable configurations to accommodate different patient preferences and needs, including a nares-only, mouth-only, or combined nares and mouth therapy options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid frame is used in the mask structure, then structural strength and stability are improved, but comfort and resistance to dislodgment deteriorate

Engineering Contradiction:
Improvestructural strengthVSAvoidcomfort and stability
Core Design Contradiction:
StrengthVSEase of operation

Solution Approach 1:

The patent applies flexible materials throughout the mask structure, including the frame, cushions, and sealing portions. The flexible frame can flexibly accommodate facial contours while maintaining structural integrity, and the flexible cushions provide comfortable contact with the patient's face without causing dislodgment. This flexibility resolves the contradiction by eliminating the rigid frame while maintaining necessary structural strength through flexible material properties.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The mask employs composite construction combining flexible frame materials with soft sealing cushions and breathable fabrics. This composite approach allows different portions of the mask to have optimized properties - structural flexibility where needed and soft comfort where contacting the face, thereby achieving both strength and comfort without rigid components.

Inventive Principle:
Principle #40Composite materials

2Adaptability or versatility

If multiple different mask systems are provided to accommodate patient preferences, then adaptability and patient choice are improved, but device complexity and cost deteriorate

Engineering Contradiction:
Improvepatient choice and preference accommodationVSAvoidnumber of different mask systems
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mask system is designed as a universal, multi-functional device that can serve multiple purposes through reconfigurable components. The same mask can be used for nasal therapy, oral therapy, or combined therapy by adjusting the positioning and configuration of the cushion assembly and frame. This eliminates the need for multiple different mask systems while maintaining adaptability to various patient preferences and therapy requirements.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mask incorporates dynamically adjustable components including reconfigurable cushion assemblies and adjustable frame elements that can be modified during use. This dynamic reconfigurability allows the mask to adapt between different therapy modes (nasal only, oral only, or combined) without requiring multiple separate mask systems, thereby reducing complexity while maintaining versatility.

Inventive Principle:
Principle #15Dynamics

3Stability of the object's composition

If a rigid frame is used to support the mask, then structural stability is improved, but the sealing portion becomes prone to dislodgment when contacted by bed clothing or pillows

Engineering Contradiction:
Improvestructural stabilityVSAvoidsealing portion retention
Core Design Contradiction:
Stability of the object's compositionVSReliability

Solution Approach 1:

The flexible frame and flexible cushions work together to provide both structural stability and retention reliability. The flexible frame maintains its shape and provides stable support while the flexible cushions can conform to the patient's face and resist dislodgment by bed clothing or pillows. This flexibility prevents the sealing portion from being dislodged while maintaining the structural integrity needed for stable mask composition.

Inventive Principle:
Principle #30Flexible shells and thin films

Data Source

PatentEP4218873B1Mask system
Publication Date: 2025.11.19 RESMED PTY LTD
  • EP4218873B1 patent drawingFigure 1-1
  • EP4218873B1 patent drawingFigure 1-2
  • EP4218873B1 patent drawingFigure 1-3

AI summary

The present invention relates to a mask system for delivery of respiratory therapy to a patient. The mask system comprises a sealing portion including a nares portion (20) and a mouth portion. The nares portion comprises a nares sealing portion (22) adapted to form a seal with the patient's nares, a nares portion chamber (49) and a connector (30). The mouth portion comprises a mouth sealing portion (42) adapted to form a seal with the patient's mouth, a mouth portion chamber (49), headgear connectors (41), and a nares portion docking station (56) with an aperture (46) configured to receive and seal with the connector (30) of the nares portion to pneumatically connect the nares portion to the mouth portion chamber (49). The mask system further comprises headgear for retaining the sealing portion in position on the head of the patient, wherein the mouth portion is connectable to at least one inlet conduit, The connector (30) is configured to pneumatically connect the nares portion (20) to the mouth portion chamber (49). The nares portion docking station has a curved upper surface that is shaped to match a curved lower surface of the nares portion.