Segmented Headgear Straps for Respiratory Mask Fit
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Solution Overview
Problem
Existing headgear assemblies for respiratory masks do not effectively accommodate a wide range of head shapes and sizes, leading to discomfort and poor fit for patients, particularly those with larger or smaller head dimensions, and are often too costly or time-consuming to customize.
Innovation Solution
A headgear assembly design with adjustable straps and a unique strap arrangement that includes upper and lower straps with varying lengths and curvatures, allowing for a common fit across different patient interfaces and accommodating various head sizes through a method that can be manufactured efficiently from flat materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If headgear assemblies are designed with fixed strap lengths and standard shapes, then manufacturing is simple and costs are low, but the assembly cannot effectively accommodate a wide range of head shapes and sizes
Solution Approach 1:
The headgear assembly is divided into multiple independent strap components (first headgear strap, second headgear strap, third headgear strap, fourth headgear strap) with different lengths and configurations. Each strap can be independently selected and adjusted to accommodate different head shapes and sizes, allowing the system to adapt to various patients without requiring complete customization of the entire assembly.
Solution Approach 2:
The headgear assembly is designed with multiple straps of varying lengths (e.g., 610mm, 660mm, 710mm, 760mm) that can serve different functions depending on the patient's needs. The same basic strap structure can be used across different patient interfaces and head sizes by selecting appropriate strap lengths and configurations, making the design universally applicable while maintaining simplicity.
2Adaptability or versatility
If headgear straps are made longer to accommodate larger heads, then larger heads can be fitted, but excess material is created when used on smaller heads
Solution Approach 1:
Instead of using a single long strap that creates excess material, the headgear is segmented into multiple straps of different lengths. Each strap is optimized for specific head size ranges, allowing precise fitting without waste. For example, shorter straps (610mm, 660mm) are used for smaller heads while longer straps (710mm, 760mm) are used for larger heads.
Solution Approach 2:
The strap length parameter is varied across different strap components to match different patient populations. By providing a range of strap lengths (610mm, 660mm, 710mm, 760mm), the system can optimize material usage for each patient's head size, eliminating the waste of excess material that would occur with a one-size-fits-all approach.
3Ease of operation
If headgear assemblies are customized to suit individual patients, then perfect fit and comfort are achieved, but production costs and time increase
Solution Approach 1:
The headgear assembly is segmented into standardized strap components that can be pre-manufactured in different lengths and configurations. These modular components can be quickly assembled to create a customized fit for each patient without requiring complete customization of the entire assembly, thus maintaining manufacturing efficiency while achieving patient-specific comfort.
Solution Approach 2:
The headgear assembly incorporates adjustable elements (such as hook and loop fasteners, sliding mechanisms) that allow dynamic adjustment of strap lengths and tensions after manufacturing. This enables customization for individual patient comfort while the base components remain standardized for efficient production.
Data Source
AI summary
A headgear assembly for attachment to a patient interface that delivers breathable gas to a patient, includes a pair of side portions and a rear portion that interconnects the pair of side portions, each of the side portions including an upper side strap and a lower side strap, the rear portion including an upper strap, a lower strap, and intermediate connecting straps extending between the upper strap and the lower strap. The headgear assembly is designed and configured so as to be used with a plurality of different mask systems, and to accommodate for variations in the anthropometrics across a wide variety of patients.