Respiratory mask with molded frame and cushion

• US 10,369,315 B2
• Filed: 12/21/2015
• Issued: 08/06/2019
• Est. Priority Date: 04/10/2003
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Inventors: Gunaratnam, Michael Kassipillai
• Primary Examiner(s): Douglas, Steven O
• Application Number:
  US14/976,006
• Publication Number:
  US 20160106943A1
• Time in Patent Office: 1,324 Days
• CPC Class Codes: A61M 16/0057 Pumps therefor
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• CPC Class Codes: A61M 16/0611 with a gusset portion
• CPC Class Codes: A61M 16/0616 with face sealing means comprising a flap or membrane projecting inwards, such that sealing increases with increasing inhalation gas pressure
• CPC Class Codes: A61M 16/0622 having an underlying cushion
• CPC Class Codes: A61M 16/0633 with forehead support
• CPC Class Codes: A61M 16/0638 in the form of a pivot
• CPC Class Codes: A61M 16/065 in the form of a pivot
• CPC Class Codes: A61M 16/0655 in the form of a linear or curvilinear slide
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production

Abstract

A fastener arrangement for securing at least two components together may include a male fastener with a first screw thread and a female fastener with a second screw thread, wherein one of the first screw thread and the second screw thread is a straight screw thread and the other of the first screw thread and the second screw thread is a hybrid screw thread that includes a tapered screw thread portion and a straight screw thread portion.

Claims

1. A respiratory mask configured to provide a supply of breathable gas to a patient'"'"'s airways at a pressure elevated in the range of 4-20 cm H2O above atmospheric pressure to treat obstructive sleep apnea, the respiratory mask comprising:

a mask frame formed from a first material, the mask frame further comprising an air inlet portion, the air inlet portion configured to be connected to an air supply conduit to receive the supply of breathable gas; and

a mask cushion formed from a second material, the mask cushion being shaped to substantially conform to the facial regions of the patient,

wherein the first material is different from the second material,

wherein the second material is more flexible and more resilient than the first material such that the mask cushion is configured to seal against the facial regions of a variety of patients, and

wherein the mask frame and the mask cushion comprise a one piece construction having a permanent, overmolded connection between the first material and the second material.

2. The respiratory mask of claim 1, wherein the first material and the second material do not readily form a chemical bond.

3. The respiratory mask of claim 1, wherein the mask frame further comprises a plurality of strap attachment portions provided on the mask frame for attaching straps to the respiratory mask to secure the respiratory mask to the head of the patient.

4. The respiratory mask of claim 1, wherein the mask frame includes portions for attaching to headgear or straps to secure the respiratory mask to the head of the patient.

5. The respiratory mask of claim 1, wherein the respiratory mask is a full-face mask or a nasal mask.

6. The respiratory mask of claim 1, wherein the mask frame further comprises a forehead support.

7. The respiratory mask of claim 6, further comprising a forehead pad attached to the forehead support.

8. The respiratory mask of claim 1, further comprising a vent.

9. A respiratory mask system configured to provide a supply of breathable gas to a patient'"'"'s airways at a pressure elevated in the range of 4-20 cm H2O above atmospheric pressure to treat obstructive sleep apnea, the respiratory mask system comprising:

the respiratory mask of claim 1; and

headgear or straps to secure the respiratory mask to the patient'"'"'s head in use.

27. The respiratory mask of claim 1, wherein the permanent, overmolded connection between the first material and the second material is at an interface between the first material and the second material.

10. A method of making a respiratory mask configured to provide a supply of breathable gas to a patient'"'"'s airways at a pressure elevated in the range of 4-20 cm H2O above atmospheric pressure to treat obstructive sleep apnea, the respiratory mask comprising:

permanently bonding together and joining by overmolding a first material and a second material together in a single process to form the respiratory mask in a single piece,

wherein a mask frame is formed from the first material, the mask frame further comprising an air inlet portion, the air inlet portion configured to be connected to an air supply conduit to receive the supply of breathable gas,

wherein a mask cushion is formed from the second material, the mask cushion being shaped to substantially conform to the facial regions of the patient,

wherein the first material is different from the second material,

wherein the second material is more flexible and more resilient than the first material such that the mask cushion is configured to seal against the facial regions of a variety of patients.

11. The method of claim 10, wherein the first material and the second material do not readily form a chemical bond.

12. The method of claim 10, further comprising forming a plurality of strap attachment portions on the mask frame for attaching straps to the respiratory mask to secure the respiratory mask to the head of the patient.

13. The method of claim 10, further comprising forming portions on the mask frame for attaching to headgear or straps to secure the respiratory mask to the head of the patient.

14. The method of claim 10, wherein the respiratory mask is a full-face mask or a nasal mask.

15. The method of claim 10, further comprising forming a forehead support on the mask frame.

16. The method of claim 15, further comprising attaching a forehead pad to the forehead support.

17. The method of claim 10, further comprising forming a vent on the respiratory mask.

28. The method of claim 10, wherein the first material and the second material are permanently bonded together and joined by overmolding at an interface between the first material and the second material.

18. A respiratory mask configured to provide a supply of breathable gas to a patient'"'"'s airways at a pressure elevated in the range of 4-20 cm H2O above atmospheric pressure to treat obstructive sleep apnea, the respiratory mask comprising:

a mask frame formed from a first material, the mask frame further comprising an air inlet portion, the air inlet portion configured to be connected to an air supply conduit to receive the supply of breathable gas; and

a mask cushion formed from a second material, the mask cushion being shaped to substantially conform to the facial regions of the patient,

wherein the first material is different from the second material,

wherein the second material is more flexible and more resilient than the first material such that the mask cushion is configured to seal against the facial regions of a variety of patients, and

wherein the mask frame and the mask cushion are permanently joined together by a direct, mechanical bond between the first material and the second material in a single process to form a single piece.

19. The respiratory mask of claim 18, wherein the first material and the second material do not readily form a chemical bond.

20. The respiratory mask of claim 18, wherein the mask frame further comprises a plurality of strap attachment portions provided on the mask frame for attaching straps to the respiratory mask to secure the respiratory mask to the head of the patient.

21. The respiratory mask of claim 18, wherein the mask frame includes portions for attaching to headgear or straps to secure the respiratory mask to the head of the patient.

22. The respiratory mask of claim 18, wherein the respiratory mask is a full-face mask or a nasal mask.

23. The respiratory mask of claim 18, wherein the mask frame further comprises a forehead support.

24. The respiratory mask of claim 23, further comprising a forehead pad attached to the forehead support.

25. The respiratory mask of claim 18, further comprising a vent.

26. A respiratory mask system configured to provide a supply of breathable gas to a patient'"'"'s airways at a pressure elevated in the range of 4-20 cm H2O above atmospheric pressure to treat obstructive sleep apnea, the respiratory mask system comprising:

the respiratory mask of claim 18; and

headgear or straps to secure the respiratory mask to the patient'"'"'s head in use.

29. The respiratory mask of claim 18, wherein the direct, mechanical bond between the first material and the second material is at an interface between the first material and the second material.