Mask assembly

• US 10,556,084 B2
• Filed: 12/17/2018
• Issued: 02/11/2020
• Est. Priority Date: 02/21/2003
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Inventors: Gunaratnam, Michael Kassipillai, Kwok, Philip Rodney, Hitchcock, Robin Garth, Veliss, Lee James, Guney, Memduh, Sokolov, Richard, Lithgow, Perry David, Darkin, Donald, Lynch, Susan Robyn
• Primary Examiner(s): Stanis, Timothy A
• Application Number:
  US16/222,735
• Publication Number:
  US 20190117927A1
• Time in Patent Office: 421 Days
• Field of Search: 12820227
• CPC Class Codes: A61M 16/0611 with a gusset portion
• CPC Class Codes: A61M 16/0622 having an underlying cushion
• CPC Class Codes: A61M 16/0633 with forehead support
• CPC Class Codes: A61M 16/0644 having the means for adjusting its position
• CPC Class Codes: A61M 16/0666 Nasal cannulas or tubing devices for improving normal breathing through the nose A61F5/08; nose filters A62B23/06; outside holding devices A61M25/02
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/08 Bellows; Connecting tubes having means for taking samples G01N1/22; Water traps; Patient circuits
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 16/0825 with ball-sockets
• CPC Class Codes: A61M 16/0833 T- or Y-type connectors, e.g. Y-piece
• CPC Class Codes: A61M 2016/0661 with customised shape

Abstract

A nasal assembly for delivering breathable gas to a patient includes a frame having an integrally formed first connector portion. A nozzle assembly includes a gusset or base portion and a pair of nozzles. At least one inlet conduit is structured to deliver breathable gas into the frame and nozzle assembly for breathing by the patient. A pair of second connector portions are removably and rotatably connected to respective first connector portions of the frame and are in communication with respective inlet conduits, e.g., directly or via angle connectors. A headgear assembly is removably connected to the pair of second connector portions and/or the angle connectors so as to maintain the frame and the nozzle assembly in a desired adjusted position on the patient'"'"'s face.

Claims

1. A mask assembly to provide pressurized air to nasal passages of a patient, comprising:

a nasal assembly shaped to seal around the nasal passages and above a mouth of the patient and deliver pressurized air to the nasal passages, a portion of the nasal assembly that is shaped to seal around the nasal passages of the patient being formed of silicone, the nasal assembly defining a breathing chamber and including;

a first nasal assembly connector portion at a first lateral side of the nasal assembly, the first nasal assembly connector portion defining a first passage permitting introduction of pressurized air into the breathing chamber, wherein the first nasal assembly connector portion is formed of a different material than the portion of the nasal assembly shaped to seal around the nasal passages, wherein the portion of the nasal assembly shaped to seal around the nasal passages of the patient is more flexible than the first nasal assembly connector portion, wherein the silicone of the portion of the nasal assembly that is shaped to seal around the nasal passages of the patient surrounds the first nasal assembly connector portion such that the silicone surrounds the first passage that permits introduction of pressurized air into the breathing chamber, and

a second nasal assembly connector portion at a second lateral side of the nasal assembly that is opposite the first lateral side of the nasal assembly, the second nasal assembly connector portion defining a second passage permitting introduction of pressurized air into the breathing chamber, wherein the second nasal assembly connector portion is formed of a different material than the portion of the nasal assembly shaped to seal around the nasal passages, wherein the portion of the nasal assembly shaped to seal around the nasal passages of the patient is more flexible than the second nasal assembly connector portion, wherein the silicone of the portion of the nasal assembly that is shaped to seal around the nasal passages of the patient surrounds the second nasal assembly connector portion such that the silicone surrounds the second passage that permits introduction of pressurized air into the breathing chamber;

a pair of inlet conduits, including a first inlet conduit and a second inlet conduit, to deliver pressurized air from a flow generator to the breathing chamber of the nasal assembly through the first passage of the first nasal assembly connector portion and the second passage of the second nasal assembly connector portion;

a first inlet conduit connector portion that is attached to an end of the first inlet conduit and is removably attachable to the first nasal assembly connector portion, the first inlet conduit connector portion defining a third passage to provide fluid communication between the first inlet conduit and the breathing chamber when the first inlet conduit connector portion is attached to the first nasal assembly connector portion, wherein the first inlet conduit connector portion is formed of a different material than the first inlet conduit; and

a second inlet conduit connector portion that is attached to an end of the second inlet conduit and is removably attachable to the second nasal assembly connector portion, the second inlet conduit connector portion defining a fourth passage to provide fluid communication between the second inlet conduit and the breathing chamber when the second inlet conduit connector portion is attached to the second nasal assembly connector portion, wherein the second inlet conduit connector portion is formed of a different material than the second inlet conduit.

2. The mask assembly of claim 1, wherein the first inlet conduit and the second inlet conduit are formed of silicone.

3. The mask assembly of claim 1, wherein:

the first nasal assembly connector portion is a rigid polymer structure; and

the second nasal assembly connector portion is a rigid polymer structure.

4. The mask assembly of claim 1, wherein:

the first nasal assembly connector portion is a rigid polymer component;

the second nasal assembly connector portion is a rigid polymer component; and

the portion of the nasal assembly shaped to seal around the nasal passages of the patient is more flexible than the first nasal assembly connector portion, and more flexible than the second nasal assembly connector portion.

5. The mask assembly of claim 1, wherein:

the first inlet conduit connector portion is insertable into the first nasal assembly connector portion to removably mate the first inlet conduit connector portion to the first nasal assembly connector portion;

the first inlet conduit connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the first nasal assembly connector portion;

the second inlet conduit connector portion is insertable into the second nasal assembly connector portion to removably mate the second inlet conduit connector portion to the second nasal assembly connector portion; and

the second inlet conduit connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the second nasal assembly connector portion.

6. The mask assembly of claim 5, wherein:

each arm of the first inlet conduit connector portion includes a rib at a free end of the respective arm; and

each arm of the second inlet conduit connector portion includes a rib at a free end of the respective arm.

7. The mask assembly of claim 5, wherein:

the first inlet conduit connector portion is configured so that when the first inlet conduit connector portion is inserted into the first nasal assembly connector portion, the arms of the first inlet conduit connector portion are initially forced toward one another during insertion and then spring outward during insertion to provide interlocking engagement between the first inlet conduit connector portion and the first nasal assembly connector portion; and

the second inlet conduit connector portion is configured so that when the second inlet conduit connector portion is inserted into the second nasal assembly connector portion, the arms of the second inlet conduit connector portion are initially forced toward one another during insertion and then spring outward during insertion to provide interlocking engagement between the second inlet conduit connector portion and the second nasal assembly connector portion.

8. The mask assembly of claim 5, wherein:

the first inlet conduit is adhered or molded to the first inlet conduit connector portion, the first inlet conduit surrounding the third passage configured to provide fluid communication between the first inlet conduit and the breathing chamber; and

the second inlet conduit is adhered or molded to the second inlet conduit connector portion, the second inlet conduit surrounding the fourth passage configured to provide fluid communication between the second inlet conduit and the breathing chamber.

9. The mask assembly of claim 1, wherein:

the first inlet conduit connector portion is removably attachable to the first nasal assembly connector portion through insertion of the nasal assembly connector portion into the first inlet conduit connector portion, and the first nasal assembly connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the first inlet conduit connector portion; and

the second inlet conduit connector portion is removably attachable to the second nasal assembly connector portion through insertion of the second nasal assembly connector portion into the second inlet conduit connector portion, and the second nasal assembly connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the second inlet conduit connector portion.

10. The mask assembly of claim 1, wherein:

the first inlet conduit connector portion is a unitary polymeric structure;

the second inlet conduit connector portion is a unitary polymeric structure;

the first inlet conduit connector portion is molded to the first inlet conduit; and

the second inlet conduit connector portion is molded to the second inlet conduit.

11. The mask assembly of claim 10, wherein:

the first inlet conduit is formed of silicone; and

the second inlet conduit is formed of silicone.

12. The mask assembly of claim 1, wherein the mask assembly is shaped to seal with a face of the patient entirely above the mouth of the patient and below a bridge of a nose of the patient.

13. The mask assembly of claim 12, wherein the nasal assembly is shaped to contact an underside of the nose of the patient and an upper lip of the patient when the nasal assembly is worn by the patient and forms the seal around the nasal passages of the patient.

14. The mask assembly of claim 1, wherein the nasal assembly includes a single gusset that is configured to expand and contract to alter a distance between:

(i) a portion of the nasal assembly that forms the seal around both of the nasal passages of the patient, and

(ii) both of the first nasal assembly connector portion and the second nasal assembly connector portion.

15. The mask assembly of claim 1, wherein:

the first inlet conduit connector portion includes means for connecting to the first nasal assembly connector portion; and

the second inlet conduit connector portion includes means for connecting to the second nasal assembly connector portion.

16. The mask assembly of claim 15, wherein:

the first inlet conduit connector portion includes means for connecting to the first inlet conduit; and

the second inlet conduit connector portion includes means for connecting to the second inlet conduit.

17. The mask assembly of claim 16, wherein the nasal assembly includes means for venting exhaust gases.

18. The mask assembly of claim 17, wherein the nasal assembly includes means for sealing with the nasal passages of the patient.

19. The mask assembly of claim 1, wherein the silicone of the portion of the nasal assembly that is shaped to seal around the nasal passages of the patient is molded around the first nasal assembly connector portion and is molded around the second nasal assembly connector portion.

20. A mask assembly to provide pressurized air to nasal passages of a patient, comprising:

a nasal assembly shaped to seal around the nasal passages and above a mouth of the patient and deliver pressurized air to the nasal passages, wherein the nasal assembly is shaped to contact an underside of a nose of the patient and an upper lip of the patient when the nasal assembly is worn by the patient and forms the seal around the nasal passages of the patient, wherein the nasal assembly avoids contacting internal surfaces of the nasal passages of the patient when the nasal assembly is worn by the patient and forms the seal around the nasal passages of the patient, wherein a portion of the nasal assembly that is shaped to seal around the nasal passages of the patient is formed of silicone, the nasal assembly defining a breathing chamber and including;

a first nasal assembly connector portion at a first lateral side of the nasal assembly, the first nasal assembly connector portion defining a first passage permitting introduction of pressurized air into the breathing chamber, wherein the silicone of the portion of the nasal assembly that is shaped to seal around the nasal passages of the patient surrounds the first nasal assembly connector portion such that the silicone surrounds the first passage that permits introduction of pressurized air into the breathing chamber, and

a second nasal assembly connector portion at a second lateral side of the nasal assembly that is opposite the first lateral side of the nasal assembly, the second nasal assembly connector portion defining a second passage permitting introduction of pressurized air into the breathing chamber, wherein the silicone of the portion of the nasal assembly shaped to seal around the nasal passages of the patient surrounds the second nasal assembly connector portion such that the silicone surrounds the second passage that permits introduction of pressurized air into the breathing chamber;

a pair of inlet conduits, including a first inlet conduit and a second inlet conduit, to deliver pressurized air from a flow generator to the breathing chamber of the nasal assembly through the first passage of the first nasal assembly connector portion and the second passage of the second nasal assembly connector portion;

a first inlet conduit connector portion that is attached to an end of the first inlet conduit and is removably attachable to the first nasal assembly connector portion, the first inlet conduit connector portion defining a third passage to provide fluid communication between the first inlet conduit and the breathing chamber when the first inlet conduit connector portion is attached to the first nasal assembly connector portion, wherein the first inlet conduit connector portion is a unitary polymeric structure, wherein the first inlet conduit connector portion is adhered to the first inlet conduit; and

a second inlet conduit connector portion that is attached to an end of the second inlet conduit and is removably attachable to the second nasal assembly connector portion, the second inlet conduit connector portion defining a fourth passage to provide fluid communication between the second inlet conduit and the breathing chamber when the second inlet conduit connector portion is attached to the second nasal assembly connector portion, wherein the second inlet conduit connector portion is a unitary polymeric structure, wherein the second inlet conduit connector portion is adhered to the second inlet conduit.

21. The mask assembly of claim 20, wherein the nasal assembly is structured to inflate upon introduction of pressurized air into the breathing chamber.

22. The mask assembly of claim 20, wherein the nasal assembly includes a vent between the first lateral side of the nasal assembly and the second lateral side of the nasal assembly.

23. The mask assembly of claim 20, wherein the silicone of the portion of the nasal assembly that is shaped to seal around the nasal passages of the patient is molded around the first nasal assembly connector portion and is molded around the second nasal assembly connector portion.

24. A mask assembly to provide pressurized air to nasal passages of a patient, comprising:

a nasal assembly shaped to seal around the nasal passages and above a mouth of the patient and deliver pressurized air to the nasal passages, wherein the nasal assembly comprises a nasal cushion that includes a portion shaped to form the seal around the nasal passages of the patient, the nasal assembly defining a breathing chamber and including;

a first nasal assembly connector portion at a first lateral side of the nasal assembly, the first nasal assembly connector portion defining a first passage permitting introduction of pressurized air into the breathing chamber, wherein the first nasal assembly connector portion is formed of a different material than the portion of the nasal assembly shaped to seal around the nasal passages, wherein the portion of the nasal assembly shaped to seal around the nasal passages of the patient is more flexible than the first nasal assembly connector portion, wherein the first nasal assembly connector portion extends to a first free edge that defines an aperture at an end of the first passage, and the nasal cushion extends toward a second free edge that ends flush with and surrounds the first free edge, and

a second nasal assembly connector portion at a second lateral side of the nasal assembly that is opposite the first lateral side of the nasal assembly, the second nasal assembly connector portion defining a second passage permitting introduction of pressurized air into the breathing chamber, wherein the second nasal assembly connector portion is formed of a different material than the portion of the nasal assembly shaped to seal around the nasal passages, wherein the portion of the nasal assembly shaped to seal around the nasal passages of the patient is more flexible than the second nasal assembly connector portion, wherein the second nasal assembly connector portion extends to a third free edge that defines an aperture at an end of the second passage, and the nasal cushion extends toward a fourth free edge that ends flush with and surrounds the third free edge;

a pair of inlet conduits, including a first inlet conduit and a second inlet conduit, to deliver pressurized air from a flow generator to the breathing chamber of the nasal assembly through the first passage of the first nasal assembly connector portion and the second passage of the second nasal assembly connector portion;

a first inlet conduit connector portion that is attached to an end of the first inlet conduit and is removably attachable to the first nasal assembly connector portion, the first inlet conduit connector portion defining a third passage to provide fluid communication between the first inlet conduit and the breathing chamber when the first inlet conduit connector portion is attached to the first nasal assembly connector portion, wherein the first inlet conduit connector portion is formed of a different material than the first inlet conduit; and

a second inlet conduit connector portion that is attached to an end of the second inlet conduit and is removably attachable to the second nasal assembly connector portion, the second inlet conduit connector portion defining a fourth passage to provide fluid communication between the second inlet conduit and the breathing chamber when the second inlet conduit connector portion is attached to the second nasal assembly connector portion, wherein the second inlet conduit connector portion is formed of a different material than the second inlet conduit.

25. The mask assembly of claim 24, wherein the nasal cushion is molded around the first nasal assembly connector portion and is molded around the second nasal assembly connector portion.

26. A mask assembly to provide pressurized air to nasal passages of a patient, comprising:

a nasal assembly shaped to seal around the nasal passages and above a mouth of the patient and deliver pressurized air to the nasal passages, the nasal assembly defining a breathing chamber and including;

a nasal cushion formed of silicone shaped to form the seal around the nasal passages, the nasal cushion shaped to not contact inside a nose of the patient when the nasal assembly is worn by the patient and the nasal cushion forms the seal around the nasal passages of the patient,

a first nasal assembly connector portion at a first lateral side of the nasal cushion, the first nasal assembly connector portion defining a first passage permitting introduction of pressurized air into the breathing chamber, wherein the first nasal assembly connector portion is formed of a different material than the nasal cushion, wherein the nasal cushion is more flexible than the first nasal assembly connector portion, wherein the silicone of the nasal cushion surrounds the first nasal assembly connector portion, and

a second nasal assembly connector portion at a second lateral side of the nasal cushion that is opposite the first lateral side of the nasal cushion, the second nasal assembly connector portion defining a second passage permitting introduction of pressurized air into the breathing chamber, wherein the second nasal assembly connector portion is formed of a different material than the nasal cushion, wherein the nasal cushion is more flexible than the second nasal assembly connector portion, wherein the silicone of the nasal cushion surrounds the second nasal assembly connector portion;

a pair of inlet conduits, including a first inlet conduit and a second inlet conduit, to deliver pressurized air from a flow generator to the breathing chamber of the nasal assembly through the first passage of the first nasal assembly connector portion and the second passage of the second nasal assembly connector portion;

a first inlet conduit connector portion that is attached to an end of the first inlet conduit and is removably attachable to the first nasal assembly connector portion, the first inlet conduit connector portion defining a third passage to provide fluid communication between the first inlet conduit and the breathing chamber when the first inlet conduit connector portion is attached to the first nasal assembly connector portion, wherein the first inlet conduit connector portion is formed of a different material than the first inlet conduit, wherein the first inlet conduit surrounds and is molded or adhered to the first inlet conduit connector portion, wherein the first inlet conduit connector portion is insertable into the first nasal assembly connector portion to removably mate the first inlet conduit connector portion to the first nasal assembly connector portion and the first inlet conduit connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the first nasal assembly connector portion; and

a second inlet conduit connector portion that is attached to an end of the second inlet conduit and is removably attachable to the second nasal assembly connector portion, the second inlet conduit connector portion defining a fourth passage to provide fluid communication between the second inlet conduit and the breathing chamber when the second inlet conduit connector portion is attached to the second nasal assembly connector portion, wherein the second inlet conduit connector portion is formed of a different material than the second inlet conduit, wherein the second inlet conduit surrounds and is molded or adhered to the second inlet conduit connector portion, wherein the second inlet conduit connector portion is insertable into the second nasal assembly connector portion to removably mate the second inlet conduit connector portion to the second nasal assembly connector portion and the second inlet conduit connector portion includes a plurality of flexible arms structured to flex radially inwardly and outwardly during insertion into the second nasal assembly connector portion.

27. The mask assembly of claim 26, wherein:

the first nasal assembly connector portion extends to a first free edge that defines an aperture at an end of the first passage;

the nasal cushion extends toward a second free edge that ends flush with and surrounds the first free edge;

the second nasal assembly connector portion extends to a third free edge that defines an aperture at an end of the second passage; and

the nasal cushion extends toward a fourth free edge that ends flush with and surrounds the third free edge.

28. The mask assembly of claim 26, wherein the nasal cushion includes a single gusset that is configured to expand and contract to alter a distance between:

(i) a portion of the nasal cushion shaped to form the seal around both of the nasal passages of the patient, and

(ii) both of the first nasal assembly connector portion and the second nasal assembly connector portion.

29. The mask assembly of claim 26, wherein:

the first inlet conduit and the nasal assembly are shaped to attach to each other without a visible step present between the first inlet conduit and the nasal assembly; and

the second inlet conduit and the nasal assembly are shaped to attached to each other without a visible step present between the second inlet conduit and the nasal assembly.

30. The mask assembly of claim 26, wherein the silicone of the nasal cushion that is shaped to form the seal around the nasal passages of the patient is molded around the first nasal assembly connector portion and is molded around the second nasal assembly connector portion.