Cushion for a respiratory mask assembly

• US 20040118406A1
• Filed: 09/05/2003
• Published: 06/24/2004
• Est. Priority Date: 09/07/2001
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Guney, Memduh, Lithgow, Perry David, Drew, Joanne Elizabeth, Kwok, Philip Rodney, Darkin, Donald, Fu, Timothy Tsun-Fai, Frater, Robert Henry
• Granted Patent: US 7,523,754 B2
• Time in Patent Office: Days
• US Class Current: 128/206.24
• 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 16/0683 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 16/0825 with ball-sockets
• CPC Class Codes: Y10T 29/4987 Elastic joining of parts

Abstract

A respiratory mark assembly for delivering breathable gas to a patient includes a frame and a cushion. The cushion has a non-face contacting portion structured to be connected to the frame, a face-contacting portion structured to engage the patient'"'"'s face, and an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion. The intermediate portion includes a gusset portion that applies a first component of force to the patient'"'"'s face through the face-contacting portion. A spring structure is coupled with the face-contacting portion of the cushion. The spring structure applies a second component of force to the patient'"'"'s face through the face-contacting portion. The first and second components of force applied by the gusset portion and spring structure, respectively, determine a contact force of the cushion applied to the patient'"'"'s face through the face-contacting portion. The intermediate portion may also include an elastic cuff portion. Further, in the case of an oral mask, the sealing section may include a portion that is designed to promote a better seal in the chin region of the mask.

Claims

1. A cushion for a respiratory mask assembly that delivers breathable gas to a patient, the cushion comprising:

a non-face contacting portion connected to a frame;

a face-contacting portion structured to engage the patient'"'"'s face; and

an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion,

the intermediate portion including a gusset portion structured to apply a first component of force to the patient'"'"'s face through the face-contacting portion; and

a spring structure coupled with the face-contacting portion, the spring structure being configured to apply a second component of force to the patient'"'"'s face through the face-contacting portion,

wherein the first and second components of force to be applied by the gusset portion and spring structure, respectively, determine a contact force to be applied to the patient'"'"'s face through the face-contacting portion.

2. The cushion according to claim 1, wherein the contact force to be applied to the patient'"'"'s face is substantially evenly distributed around the entire perimeter of the cushion.

3. The cushion according to claim 1, wherein the contact force to be applied to the patient'"'"'s face in a nasal bridge region is less than the contact force to be applied to the patient'"'"'s face in cheek regions.

4. The cushion according to claim 1, wherein the contact force to be applied to the patient'"'"'s face by the cushion in a sensitive region of the face is less than the contact force to be applied to the patient'"'"'s face by the cushion in a less sensitive region of the face.

5. The cushion according to claim 1, wherein the intermediate portion extends radially outwardly a distance away from the non-face-contacting and face-contacting portions to provide additional footprint area outside a contact line of the cushion.

6. The cushion according to claim 5, wherein the gusset portion has a first side wall extending outwardly from the face-contacting portion, a second side wall extending outwardly from the non-face-contacting portion, and an arcuate wall that interconnects the first and second side walls, the first wall, the second wall and the arcuate wall of the gusset portion defining the additional footprint area therebetween.

7. The cushion according to claim 6, wherein a distance between the arcuate wall of the gusset portion and the contact line of the cushion defines a dimension that is at least partially determinative of the first component of force to be applied to the patient'"'"'s face.

8. The cushion according to claim 6, wherein the arcuate wall acts as the spring structure to provide the second component of force to the patient'"'"'s face through the face-contacting portion, the arcuate wall having a thickness that is designed to allow adjustment of the second component of force.

9. The cushion according to claim 1, wherein the gusset portion has a dimension that is designed to be variable in different regions of the gusset portion to adjust the first component of force to be applied to different regions of the patient'"'"'s face.

10. The cushion according to claim 1, wherein the non-face-contacting portion is removably connected to the frame.

11. The cushion according to claim 10, wherein the non-face-contacting side is removably connected to the frame with a cushion clip.

12. The cushion according to claim 1, wherein the face-contacting portion includes a side wall, a rim extending away from the side wall, and a membrane provided to substantially surround the rim.

13. The cushion according to claim 12, wherein the cushion includes two or more rims and a membrane to substantially surround the two or more rims.

14. The cushion according to claim 12, wherein the cushion includes a rim and two or more membranes to substantially surround the rim.

15. The cushion according to claim 1, wherein the face contacting portion comprises a gel portion.

16. The cushion according to claim 1, wherein the face-contacting portion has a generally triangular shape.

17. The cushion according to claim 1, wherein the gusset portion is curved to follow the contour of the patient'"'"'s face.

18. The cushion according to claim 1, wherein the face-contacting portion is designed to apply different contact forces to different regions of the patient'"'"'s face at a given mask pressure.

19. The cushion according to claim 1, wherein the gusset portion is structured to not impinge on the patient'"'"'s vision.

20. The cushion according to claim 1, wherein the gusset portion is structured to follow the curvature of the patient'"'"'s face to reduce a height profile of the gusset portion.

21. The cushion according to claim 1, wherein the gusset portion has recessed portions to allow the patient'"'"'s field of view to be unimpeded.

22. The cushion according to claim 1, wherein the spring structure is provided by at least one spring positioned within the gusset portion, the at least one spring having a spring constant that is designed to allow adjustment of the second component of force.

23. The cushion according to claim 1, wherein the gusset portion includes a dimension that is at least partially determinative of the first component of force to be applied to the patient'"'"'s face.

24. The cushion according to claim 1, wherein the at least one spring and the gusset portion are designed to allow adjustment of the first and second components of force, respectively, so as to allow adjustment of the contact force to be applied to different regions of the patient'"'"'s face.

25. A respiratory mask assembly for delivering breathable gas to a patient, comprising:

a frame; and

a cushion according to claim 1.

26. A method for improving the comfort of a respiratory mask assembly for delivering breathable gas to a patient, comprising:

providing a cushion having at least a face-contacting portion structured to engage the patient'"'"'s face and apply a contact force on the patient'"'"'s face; and

designing the cushion to redistribute the contact force on the patient'"'"'s face away from a first region of the patient'"'"'s face and onto a second region of the patient'"'"'s face.

27. The method according to claim 26, further comprising:

providing a gusset portion within the cushion that is determinative of a component of the contact force to be applied to the patient'"'"'s face through the face-contacting portion, the gusset portion having a first outer perimeter that defines an outer perimeter of the gusset portion and a second outer perimeter that defines an outer perimeter of a sealing strip of a seal forming portion of the cushion; and

varying a distance between the first and second outer perimeters of the gusset portion in different regions of the patient'"'"'s face to thereby vary the contact force applied in different regions of the patient'"'"'s face.

28. The method according to claim 26, further comprising:

providing a spring structure within the cushion that is determinative of a component of contact force applied to the patient'"'"'s face through the face-contacting portion, the spring structure having a spring constant; and

varying the spring constant of the spring structure in different regions of patient'"'"'s face to thereby vary the contact force applied in different regions of the patient'"'"'s face.

29. The method according to claim 26, wherein the spring structure and cushion are formed in one piece.

30. A cushion for a respiratory mask assembly that delivers breathable gas to a patient, the cushion comprising:

a non-face contacting portion connected to a frame; and

a face-contacting portion structured to engage the patient'"'"'s face and apply a contact force on the patient'"'"'s face,

wherein the face-contacting portion is structured such that the contact force on the patient'"'"'s face can be redistributed away from a first region of the patient'"'"'s face and onto a second region of the patient'"'"'s face.

31. The cushion according to claim 30, wherein the first region is a sensitive region of the patient'"'"'s face and the second region is a less sensitive region of the patient'"'"'s face.

32. A cushion for a respiratory mask assembly that delivers breathable gas to a patient, the cushion comprising:

a non-face contacting portion connected to a frame;

a face-contacting portion structured to engage the patient'"'"'s face; and

an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion, the intermediate portion including a gusset portion to apply a component of force to the patient'"'"'s face through the face-contacting portion,

wherein at least the gusset portion is curved as viewed from above to follow the contour of the patient'"'"'s face.

33. The cushion according to claim 32, wherein the gusset portion has a radius of curvature in the range of 80-120 mm.

34. A respiratory mask assembly for delivering breathable gas to a patient, comprising:

a frame;

a cushion having a non-face contacting portion connected to the frame, a face-contacting portion structured to engage the patient'"'"'s face and apply a contact force on the patient'"'"'s face, and an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion,

the intermediate portion including a gusset portion that is determinative of a component of the contact force to be applied to the patient'"'"'s face through the face-contacting portion, the gusset portion having a first outer perimeter that defines an outer perimeter of the gusset portion and a second outer perimeter that defines an outer perimeter of a sealing strip of a seal forming portion of the cushion,

wherein a distance between the first and second outer perimeters of the gusset portion can be varied in different regions of the patient'"'"'s face to thereby vary the contact force applied in different regions of the patient'"'"'s face.

35. A respiratory mask assembly for delivering breathable gas to a patient, comprising:

a frame;

a cushion having a non-face contacting portion connected to the frame, a face-contacting portion structured to engage the patient'"'"'s face and apply a contact force on the patient'"'"'s face, and an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion,

the intermediate portion including a gusset portion that is determinative of a component of the contact force applied to the patient'"'"'s face through the face-contacting portion, the gusset portion having a first outer perimeter that defines an outer perimeter of the gusset portion and a second outer perimeter that defines an outer perimeter of a sealing strip of a seal forming portion of the cushion,

wherein a distance between the first and second outer perimeters of the gusset portion in a nasal bridge contacting region of the cushion differs from a distance between the first and second outer perimeters of the gusset portion in a cheek contacting region of the cushion to thereby differ the contact force to be applied by the nasal bridge contacting region from the contact force applied by the cheek contacting region.

36. The respiratory mask assembly according to claim 35, wherein a distance between the first and second outer perimeters of the gusset portion in a nasal bridge contacting region is smaller than a distance between the first and second outer perimeters of the gusset portion in a cheek contacting region.

37. A respiratory mask comprising:

a frame including a breathable gas port, wherein the frame defines an inner chamber to receive at least one of a wearer'"'"'s nasal region and mouth; and

a cushion including a flange connected to the frame, an inner rim defining an opening to the inner chamber of the frame, and a sealing portion disposed between the flange and the inner rim to contact the wearer'"'"'s face,

wherein the sealing portion includes a nasal seal section to span a wearer'"'"'s face above the wearer'"'"'s nares, side seal sections extending from each side of the nasal seal section on both sides of the wearer'"'"'s mouth, and a chin seal section that extends between the side seal sections, wherein the chin seal section is upwardly curved in an arch to follow the chin'"'"'s bony contour.

38. The respiratory mask of claim 37, wherein the chin seal section is one of an inverted U-shape, W-shaped and boomerang shaped.

39. The respiratory mask of claim 37, wherein the side seal sections are structured to extend downward to the wearer'"'"'s lower jaw.

40. The respiratory mask of claim 37, wherein the wearer has a bottom lip and a mental protuberance and the chin seal section is structured to be positioned between the wearer'"'"'s bottom lip and the mental protuberance.

41. The respiratory mask of claim 37, wherein the sealing portion is thinner than the rim.

42. The respiratory mask of claims 37, wherein the sealing portion is a lip that extends beyond the rim.

43. The respiratory mask of claim 37, wherein the cushion and the frame are integral.

44. The respiratory mask of claim 37, wherein the cushion is removably attached to the frame.

45. The respiratory mask of claim 37, wherein the cushion is made of a silicone elastomer.

46. The respiratory mask of claim 37, wherein the cushion comprises a combination of materials that are assembled together.

47. The respiratory mask of claim 37, wherein the cushion comprises a combination of integrally formed materials.

48. The respiratory mask of claim 37, wherein the cushion is made of gel.

49. The respiratory mask of claim 37, wherein the cushion is made of foam.

50. The respiratory mask of claim 49, wherein the cushion is made of gel and foam.

51. The respiratory mask of claim 37, wherein the frame is generally triangular.

52. The respiratory mask of claim 37, wherein the cushion is made of silicone and gel.

53. The respiratory mask of claim 37, wherein the frame is generally trapezoidal.

54. The respiratory mask of claim 37, wherein the frame includes a vent.

55. The respiratory mask of claim 37, wherein the frame includes head strap fasteners.

56. The respiratory mask of claim 37, wherein the sealing portion defines an inverted U-shaped seal section that is adjustable to fit the contour of the wearer'"'"'s face.

57. A cushion for use in a respiratory mask, comprising:

a flange to connect to a mask frame;

an inner rim defining an opening to surround at least one of the wearer'"'"'s nares and mouth; and

a sealing portion disposed between the flange and the inner rim to contact the wearer'"'"'s face,

wherein the sealing portion includes a nasal seal section to span a wearer'"'"'s face above the wearer'"'"'s nares, side seal sections extending from each side of the nasal section on both sides of the wearer'"'"'s mouth, and a chin seal section that extends between the side seal sections, wherein the chin seal section is upwardly curved in an arch to follow the chin'"'"'s bony contour.

58. The cushion of claim 57, wherein the side seal sections extend downward to cover at least a portion of the wearer'"'"'s lower jaw.

59. The cushion of claim 57, wherein the wearer has a bottom lip and a mental protuberance and the chin seal section is positionable between the wearer'"'"'s bottom lip and the mental protuberance.

60. The cushion of claim 57, wherein the sealing portion is thinner than the rim.

61. The cushion of claim 57, wherein the sealing portion is a lip that extends beyond the rim.

62. The cushion of claim 57 made of a silicone elastomer, gel and/or foam.

63. The cushion of claim 57, in combination with a respiratory mask including a frame, wherein the cushion is supported by the frame.

64. The cushion of claim 57, wherein the opening is structured to cover only the wearer'"'"'s mouth.

65. A respiratory mask assembly for delivering breathable gas to a patient, comprising:

a frame; and

a cushion having a non-face contacting portion connected to the frame, a face-contacting portion structured to apply a contact force on the patient'"'"'s face, and an intermediate portion that interconnects the non-face contacting portion and the face-contacting portion,

wherein the intermediate portion includes an elastic cuff portion that is at least partly determinative of a component of the contact force to be applied to the patient'"'"'s face through the face-contacting portion, the elastic cuff portion having a stiffness which is less than the stiffness of at least one of the face contacting portion and the non-face contacting portion.

66. A cushion comprising:

a non-face contacting portion connected to the frame;

a face-contacting portion structured to apply a contact force on the patient'"'"'s face; and

an intermediate portion that interconnects the non-face contacting portion and the face contacting portion, the intermediate portion including at least one elastic cuff portion that is at least partly determinative of a component of the contact force to be applied to the patient'"'"'s face through the face-contacting portion, the at least one elastic cuff portion having a stiffness which is less than the stiffness of at least one of the face contacting portion and the non-face contacting portion.

67. The cushion of claim 66, wherein the at least one elastic cuff portion extends about the entire perimeter of the cushion.

68. The cushion of claim 66, wherein the at least on elastic cuff portion is provided along only a limited portion of the intermediate portion of the cushion.

69. The cushion of claim 68, wherein the cushion includes a base portion and an obliquely angled side portion provided to each side of the base portion, and the at least one elastic cuff portion is provided along the base portion.

70. The cushion of claim 68, wherein the at least one elastic cuff portion includes two elastic cuff portions provided symmetrically about the intermediate portion.