Over-moulded Plastic Textile Coupling for Patient Interface

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Solution Overview

Problem

Existing respiratory disorder treatment devices, such as those for Obstructive Sleep Apnea, are often uncomfortable, poorly fitting, and noisy, with patient interfaces that require constant adjustment and cleaning, and vents that can be disruptive and difficult to maintain.

Innovation Solution

A patient interface with a seal-forming structure that uses a combination of soft materials for the seal and rigid components for stability, featuring a plenum chamber and connection portions that are easy to clean and attach, and a textile portion with over-moulded plastic elements for durability and comfort, designed to provide a secure and quiet fit during therapy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a patient interface uses soft materials for the seal-forming structure, then comfort and ease of use are improved, but structural stability and durability may deteriorate

Engineering Contradiction:
Improvecomfort and ease of useVSAvoidstructural stability and durability
Core Design Contradiction:
Ease of operationVSStrength

Solution Approach 1:

The patient interface combines soft seal-forming materials (such as silicone or rubber) with rigid structural components (such as plastic or metal frames). The soft materials contact the patient's face to provide comfort and conformability, while the rigid components provide structural stability, shape retention, and durability. This composite construction allows each material to perform its optimal function without compromising the other.

Inventive Principle:
Principle #40Composite materials

2Adaptability or versatility

If the patient interface requires constant adjustment and cleaning, then adaptability is improved, but ease of operation deteriorates

Engineering Contradiction:
ImproveadjustabilityVSAvoidease of use
Core Design Contradiction:
Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patient interface incorporates adjustable components such as movable headgear straps, adjustable cushion positions, and flexible connection points that allow the interface to adapt to different patient faces and preferences. These dynamic elements enable customization while maintaining ease of operation through simple adjustment mechanisms that do not require complex procedures or frequent maintenance.

Inventive Principle:
Principle #15Dynamics

3Adaptability or versatility

If vents are added to the patient interface, then functionality is improved, but noise and difficulty of maintenance increase

Engineering Contradiction:
ImprovefunctionalityVSAvoidnoise
Core Design Contradiction:
Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The vent components are designed using flexible materials and streamlined structures that minimize turbulence and noise generation during breath passage. The vent openings are positioned and shaped to reduce air flow noise, and the surrounding flexible materials help dampen sound transmission. This allows the vents to provide necessary functionality (exhalation relief, pressure regulation) while minimizing the harmful noise effect.

Inventive Principle:
Principle #30Flexible shells and thin films

4Reliability

If the patient interface is made more secure and stable, then reliability is improved, but comfort and ease of use may deteriorate

Engineering Contradiction:
Improvesecure seal and stabilityVSAvoidcomfort
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patient interface applies different material properties and structural characteristics to different regions: the seal-forming portions use soft, compliant materials for comfort and conformability; the headgear and structural framework use rigid, stable materials for security and stability; the connection areas use flexible elements for adaptability. This localized differentiation allows the interface to achieve secure sealing and stability without compromising patient comfort in the contact regions.

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 solution enhances comfort and ease of use by providing a lightweight, unobtrusive, and quiet patient interface that is intuitive to connect and adjust, while maintaining a secure seal and facilitating easy cleaning, thus improving treatment efficacy for respiratory disorders.

Implementation Method 1

a plastic portion (204) formed of a thermoplastic material having a melting point, the plastic portion over-moulded to the textile portion

Methodology Applied
Scientific EffectMelting: Melting

Implementation Method 2

the plastic portion over-moulded to the textile portion

Methodology Applied
Scientific EffectSolidification: Freezing

Data Source

PatentUS11986596B2Plastic to textile coupling for a patient interface and methods of manufacturing same
Publication Date: 2024.05.21 RESMED PTY LTD
  • US11986596B2 patent drawing
  • US11986596B2 patent drawing
  • US11986596B2 patent drawing

AI summary

A manufactured component, such as headgear or a headgear strap, for a patient interface for delivery of pressurised air or breathable gas to an entrance of a patient's airways may include a textile portion having a first material with a first melting point. It may also include a plastic portion over-moulded to the textile portion. The plastic portion may be formed of a second material having a second melting point. The melting points may be different such that the second melting point is chosen to be less than the first melting point of the first material. The component may be moulded in a multi-step process that moulds separate portions of the plastic portion and the textile portion at different times. The resulting plastic portion may then have a mechanical bond with the textile and may do so without significant chemical bonding between the plastic portion and the textile.