Woven and Knitted Respiratory Vent Diffusers for Quieter, Cleaner Airflow
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Solution Overview
Problem
Existing diffuser pads for CPAP systems, made of non-woven polyester fibers, suffer from poor bonding strength, difficulty in cleaning, and quick dirt accumulation, leading to noise and aesthetic issues.
Innovation Solution
Implementing diffuser pads formed from woven or knitted materials with improved thread interlocking and surface textures, along with removable and replaceable diffuser elements, to enhance durability and airflow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If non-woven polyester fiber pads are used as diffusers, then noise reduction is achieved, but bonding strength between strands is poor and cleaning becomes difficult
Solution Approach 1:
The patent changes the fundamental material parameter from non-woven to knitted fabric structure. This structural parameter change provides inherent bonding strength through the interlocking loop formation of yarns, while maintaining the diffuser functionality for noise reduction through the fabric's porous structure.
Solution Approach 2:
The patent employs composite construction by combining knitted fabric with adhesive layers or coating materials. The knitted fabric provides structural integrity and bonding strength, while the adhesive or coating layers enhance the bonding between strands and improve cleanability by creating a smoother surface that resists dirt accumulation.
2Object-affected harmful factors
If non-woven polyester fiber pads are used as diffusers, then noise reduction is achieved, but dirt particles are readily trapped and visual appearance deteriorates quickly
Solution Approach 1:
The patent changes the surface parameter by selecting knitted fabric with smoother surface characteristics compared to non-woven materials. The knitted structure's inherent smoothness reduces dirt particle trapping, thereby maintaining visual appearance longer while preserving noise reduction properties through the fabric's porous diffuser structure.
Solution Approach 2:
The patent addresses visual appearance by incorporating colorfast dyes or coatings on the knitted fabric surface. This prevents dirt-related visual deterioration and maintains aesthetic appeal, while the underlying knitted structure continues to provide noise reduction functionality.
3Strength
If woven or knitted materials are used for diffuser pads, then bonding strength and cleanability are improved, but manufacturing complexity may increase
Solution Approach 1:
The patent segments the diffuser pad into distinct functional layers: a knitted fabric layer providing bonding strength and structure, and separate adhesive or coating layers enhancing strand bonding and cleanability. This segmentation allows each layer to be optimized independently and manufactured through specialized processes, then assembled into the final product.
Solution Approach 2:
The patent employs universal knitted fabric bases that can serve multiple functions: providing structural bonding strength, creating a smooth surface for improved cleanability, and offering a consistent substrate for adhesive application. This multi-functionality reduces the need for multiple specialized components, thereby simplifying the overall manufacturing process despite the upgraded material.
Data Source
AI summary
A diffuser element for use over a vent opening of a breathing assistance apparatus. In some configurations, the diffuser element is formed by knitting or weaving one or more threads together into an interlocking pattern. In some configurations, the diffuser pad has a first surface and an opposing second surface and at least the first surface includes a surface texture. Arrangements for coupling the diffuser element to a structure that defines or carries the vent are also disclosed.