Cushion for Patient Interface

• US 20080110464A1
• Filed: 01/12/2006
• Published: 05/15/2008
• Est. Priority Date: 01/12/2005
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Davidson, Aaron Samuel, Hitchcock, Robin Garth, Worboys, David John, Lynch, Susan Robyn, Eves, Matthew
• Granted Patent: US 8,220,459 B2
• Time in Patent Office: Days
• US Class Current: 128/206.26
• 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: A62B 18/08 Component parts for gas-masks or gas-helmets, e.g. windows, straps, speech transmitters, signal-devices eye-pieces for protective goggles A61F9/02; composition of materials for the windows or other transparent parts A62D7/00
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

A cushion for a patient interface that delivers breathable gas to a patient includes a base wall structured to be connected to a frame, an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use, and a membrane provided to substantially cover at least a portion of the underlying cushion. The membrane is adapted to form a continuous seal on the patient'"'"'s face. The underlying cushion has a spring-like connection with the base wall. The underlying cushion and/or base wall define a spring constant that varies along a length of the seal.

Claims

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

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane including nasal bridge, cheek, and chin regions adapted to form a continuous seal on nasal bridge, cheek, and chin regions of the patient'"'"'s face, respectively, the nasal bridge and adjacent two cheek regions defining an intersection,

wherein the membrane in the nasal bridge region has a height at the intersection that is greater than a height in an adjacent portion of the cheek region.

2. The cushion according to claim 1, wherein the membrane in the nasal bridge region has a rolled edge.

3. The cushion according to claim 1, wherein the height is measured at a peak of the intersection.

4. The cushion according to claim 1, wherein the underlying cushion is provided only on lateral sides of the base wall in the cheek region of the membrane.

5. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein the underlying cushion has a spring-like connection with the base wall, the underlying cushion and/or base wall defining a spring constant that varies along a length of the seal.

6. The cushion according to claim 5, wherein the membrane includes five distinct regions, and the spring constant varies in at least three of the five distinct regions.

7. The cushion according to claim 5, wherein the cushion is a nasal cushion.

8. The cushion according to claim 7, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

9. The cushion according to claim 5, wherein the cushion is a full-face cushion.

10. The cushion according to claim 9, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

11. The cushion according to claim 10, wherein the underlying cushion is provided only on lateral sides of the base wall in the side of nose, upper cheek, and lower cheek regions.

12. The cushion according to claim 10, wherein the underlying cushion is less stiff in the upper and lower cheek regions than in the side of nose region.

13. The cushion according to claim 10, wherein the underlying cushion is less stiff in the lower cheek region than in the upper cheek region.

14. The cushion according to claim 5, wherein at least a portion of the underlying cushion and/or base wall has a lower portion including a spring configuration that defines displacement of the cushion with respect to a force applied from the frame.

15. The cushion according to claim 5, wherein the underlying cushion and/or base wall has a question-mark or sickle shape.

16. The cushion according to claim 5, wherein spring characteristics of the underlying cushion are determined by at least one of an underlying cushion height, an underlying cushion thickness, an underlying cushion radius, and an underlying cushion offset.

17. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein one of the membrane and the underlying cushion includes an external surface that defines an outer width of the cushion, and the base wall is internally offset with respect to the external surface.

18. The cushion according to claim 17, wherein a depth of the base wall internal offset is different in different regions of the cushion, and the depth is at least partially determinative of spring-like characteristics.

19. The cushion according to claim 17, wherein the cushion is a nasal cushion.

20. The cushion according to claim 19, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

21. The cushion according to claim 17, wherein the cushion is a full-face cushion.

22. The cushion according to claim 21, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

23. The cushion according to claim 22, wherein the underlying cushion is provided only on lateral sides of the base wall in the side of nose, upper cheek, and lower cheek regions.

24. The cushion according to claim 17, wherein the underlying cushion provides the external surface.

25. The cushion according to claim 17, wherein at least a portion of the underlying cushion and/or base wall has a lower portion including a spring configuration that defines displacement of the cushion with respect to a force applied from the frame.

26. The cushion according to claim 17, wherein the underlying cushion and/or base wall has a question-mark or sickle shape.

27. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane including at least nasal bridge and side of nose regions adapted to form a continuous seal on nasal bridge and side of nose regions of the patient'"'"'s face, respectively,

wherein the base wall and the underlying cushion in the side of nose region are inclined or angled with respect to a bottom of the frame.

28. The cushion according to claim 27, wherein the cushion is a nasal cushion.

29. The cushion according to claim 28, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

30. The cushion according to claim 27, wherein the cushion is a full-face cushion.

31. The cushion according to claim 30, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

32. The cushion according to claim 27, wherein the base wall and the underlying cushion in the side of nose region are angled in the range of 15-25 degrees with respect to the bottom of the frame.

33. The cushion according to claim 32, wherein the base wall and the underlying cushion in the side of nose region are angled 22 degrees with respect to the bottom of the frame.

34. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane including nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively,

wherein an inner edge of the membrane defines an aperture that receives the patient'"'"'s nose and mouth, and a lower portion of the aperture that receives the patient'"'"'s mouth has a mouth width that remains substantially constant irrespective of a face height of the cushion.

35. The cushion according to claim 34, wherein the mouth width is constant for all cushion sizes.

36. The cushion according to claim 35, wherein the mouth width is 60 mm for all cushion sizes.

37. The cushion according to claim 34, wherein the mouth width is almost constant for all cushion sizes.

38. The cushion according to claim 37, wherein the mouth width is 60 mm ±

5 for all cushion sizes.

39. The cushion according to claim 34, wherein the aperture has a generally triangular shape.

40. The cushion according to claim 34, wherein the mouth width is greater than about 54 mm.

41. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein at least a portion of the underlying cushion and/or base wall has a lower portion including a spring configuration that defines displacement of the cushion with respect to a force applied from the frame.

42. The cushion according to claim 41, wherein the cushion is a nasal cushion.

43. The cushion according to claim 42, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

44. The cushion according to claim 41, wherein the cushion is a full-face cushion.

45. The cushion according to claim 44, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

46. The cushion according to claim 41, wherein the underlying cushion has a spring-like connection with the base wall.

47. The cushion according to claim 41, wherein the membrane has a free end that is vertically and horizontally spaced from a free end of the underlying cushion.

48. The cushion according to claim 41, wherein the lower portion of the underlying cushion has a substantially arcuate configuration that defines a flexing space below the lower portion and adjacent to the base wall.

49. The cushion according to claim 48, wherein the space has a depth less than about 4.0 mm.

50. The cushion according to claim 49, wherein the space has a depth of about 3.0 mm.

51. The cushion according to claim 44, wherein an inner edge of the membrane defines a generally triangular-shaped aperture that receives the patient'"'"'s nose and mouth, and an apex of the aperture has a notch having a radius of curvature in the range of 1.5-6.0 mm.

52. The cushion according to claim 51, wherein the notch has a radius of curvature of about 3.0 mm.

53. The cushion according to claim 45, wherein the underlying cushion is provided only on lateral sides of the base wall in the side of nose, upper cheek, and lower cheek regions of the membrane.

54. The cushion according to claim 45, wherein the membrane forms an elongated ridge in the nasal bridge region, the elongated ridge having sloping sides that meet to form an elongated crest, and wherein each of the sloping sides is angled from a crest centerline in the range of 30-60°

and the crest has a radius of curvature in the range of 1.0-5.0 mm.

55. The cushion according to claim 54, wherein each of the sloping sides is angled from a crest centerline by about 40°

-50°

, preferably 47°

, and the crest has a radius of curvature of about 2.5 mm.

56. The cushion according to claim 54, wherein a forward portion of the elongated ridge has an arcuate configuration having a radius of curvature in the range of 1.5-7.0 mm.

57. The cushion according to claim 56, wherein the forward portion has a radius of curvature of about 4.0 mm.

58. The cushion according to claim 54, wherein the elongated ridge is structured to invert its configuration upon engagement with the patient'"'"'s nasal bridge region.

59. The cushion according to claim 58, wherein a leading edge of the elongated ridge is adapted to roll as the elongated ridge inverts its configuration.

60. The cushion according to claim 46, wherein the nasal bridge region of the membrane includes a contoured portion that curves inwardly towards a cavity of the cushion along a radius to terminate at an inner edge of the membrane, the contoured portion having a free end that is angled with respect to a face contacting plane of the cushion in the range of 30-50°

.

61. The cushion according to claim 60, wherein the contoured portion is angled about 40°

with respect to a face contacting plane of the cushion.

62. The cushion according to claim 41, wherein the underlying cushion and/or base wall has a question-mark or sickle shape.

63. The cushion according to claim 44, wherein an inner edge of the membrane defines a generally triangular-shaped aperture that receives the patient'"'"'s nose and mouth, and a lower portion of the aperture that receives the patient'"'"'s mouth has a width greater than about 54 mm.

64. The cushion according to claim 43, wherein the membrane in the nasal bridge region has a substantially flat portion in elevation view.

65. A method of designing a series of mask assemblies, comprising:

providing a first cushion adapted to fit a larger range of patients; and

providing a second cushion adapted to fit a smaller range of patients,

wherein each of the first and second cushions includes an aperture that receives at least the patient'"'"'s mouth, the aperture of the first and second cushions having the same width.

66. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane including at least a nasal bridge region adapted to form a continuous seal on a nasal bridge region of the patient'"'"'s face,

wherein the membrane forms an elongated ridge in the nasal bridge region, the elongated ridge having sloping sides that meet to form an elongated crest, and wherein each of the sloping sides is angled from a crest centerline in the range of 30-60° and

the crest has a radius of curvature in the range of 1.0-5.0 mm.

67. The cushion according to claim 66, wherein the cushion is a nasal cushion.

68. The cushion according to claim 67, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

69. The cushion according to claim 66, wherein the cushion is a full-face cushion.

70. The cushion according to claim 69, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

71. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane including at least a nasal bridge region adapted to form a continuous seal on a nasal bridge region of the patient'"'"'s face,

wherein the nasal bridge region of the membrane includes a contoured portion that curves inwardly towards a cavity of the cushion along a radius to terminate at an inner edge of the membrane, the contoured portion having a free end that is angled with respect to a face contacting plane of the cushion in the range of 30-50°

.

72. The cushion according to claim 71, wherein the cushion is a nasal cushion.

73. The cushion according to claim 72, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

74. The cushion according to claim 71, wherein the cushion is a full-face cushion.

75. The cushion according to claim 74, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

76. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein the underlying cushion and/or base wall has a question-mark or sickle shape.

77. The cushion according to claim 76, wherein the cushion is a nasal cushion.

78. The cushion according to claim 77, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

79. The cushion according to claim 76, wherein the cushion is a full-face cushion.

80. The cushion according to claim 79, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

81. The cushion according to claim 76, wherein the underlying cushion and/or base wall include a linear portion and a curved portion, and the linear portion has an longitudinal axis that extends through the curved portion.

82. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein the underlying cushion has an arcuate configuration including an arc length greater than 16 mm.

83. The cushion according to claim 82, wherein the arc length is in the range of 16-30 mm.

84. The cushion according to claim 82, wherein the arc length is in the range of 20-25 mm.

85. The cushion according to claim 82, wherein the arc length is in the range of 22-24 mm.

86. The cushion according to claim 82, wherein the arc length is 22.84 mm.

87. The cushion according to claim 82, wherein the arc length is in the range of 16-20 mm.

88. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame;

an underlying support cushion extending away from the base wall towards the patient'"'"'s face in use; and

a membrane provided to substantially cover at least a portion of the underlying cushion, the membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein the membrane includes a thickness that varies along a length of the seal.

89. The cushion according to claim 88, wherein the cushion is a nasal cushion.

90. The cushion according to claim 89, wherein the membrane includes nasal bridge, side of nose, and upper lip regions adapted to form a continuous seal on nasal bridge, side of nose, and upper lip regions of the patient'"'"'s face, respectively.

91. The cushion according to claim 88, wherein the cushion is a full-face cushion.

92. The cushion according to claim 91, wherein the membrane includes nasal bridge, side of nose, upper cheek, lower cheek and chin regions adapted to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek, and chin regions of the patient'"'"'s face, respectively.

93. The cushion according to claim 92, wherein the membrane in the nasal bridge region and upper cheek region has a thickness of 0.3 mm which transitions to a thickness of 0.5 mm in the upper cheek region and maintains a thickness of 0.5 mm in the lower cheek and chin regions.

94. A cushion for a patient interface that delivers breathable gas to a patient, the cushion comprising:

a base wall structured to be connected to a frame; and

a membrane adapted to form a continuous seal on the patient'"'"'s face,

wherein at least a portion of the base wall includes a tapered portion that tapers towards the membrane.

95. The cushion according to claim 94, wherein the tapered portion is provided in a nasal bridge region.

96. A mask system comprising:

a set of at least two cushions arranged to suit different face sizes,

wherein the at least two cushions have substantially the same width.