CUSHION, METHOD OF AND APPARATUS FOR MOLDING A CUSHION FOR A RESPIRATORY MASK

• US 20110174310A1
• Filed: 07/22/2009
• Published: 07/21/2011
• Est. Priority Date: 07/22/2008
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: MAP Medizin-Technologie GMBH (ResMed Incorporated)
• Inventors: Lang, Bernd, Burz, Johann S., Biener, Achim, Nickol, Johannes
• Granted Patent: US 10,195,775 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 16/0616 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 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: B29C 45/4407 by flexible movement of undercut portions of the articles
• CPC Class Codes: B29K 2083/005 LSR, i.e. liquid silicone rubbers, or derivatives thereof

Abstract

The present invention is related to a cushion (1) for a respiratory mask, to a method of manufacturing such a cushion (1) as well as to a respiratory mask including a cushion (1) and an apparatus for manufacturing a cushion (1) for a respiratory mask. It is particularly referred to a method of manufacturing a cushion (1) for a respiratory mask, comprising the steps of providing a mold comprising at least two mold halves (11, 13) and at least one core (12) therein, closing the mold, injecting a first material into the mold to form the cushion (1), wherein the core (12) is enclosed by the cushion (1) thereby forming at least one cavity (4), opening the mold, removing the core (12) from the cushion (1) to provide the at least one cavity within the cushion (1), and sealing the cavity (4).

Claims

1. Method of manufacturing a cushion (1) for a respiratory mask, comprising the steps of providing a mold comprising at least two mold halves (11, 12, 13) and at least one core (15) therein, closing the mold, injecting a first material into the mold to form the cushion (1), wherein the core (15) 0is enclosed by the cushion (1) thereby forming at least one cavity (4), opening the mold, removing the core (15) from the cushion (1) to provide the at least one cavity (4) within the cushion (1), and sealing the cavity (4), wherein the core (15) is C-shaped.

2. Method according to claim 1, wherein the step of removing the core (15) from the cushion (1) comprises displacing the care (15) together with the cushion (1) relative to the mold halves (11, 12, 13).

3. Method according to claim 1, wherein the step of removing the core (15) from the cushion (1) leaves a single orifice (3) in the cushion.

4. Method according to claim 1, wherein the cavity (4) is sealed by injecting the first material into the orifice (3), by gluing an insert into or a patch over the orifice (3) and/or by overmolding the cushion (1) including the orifice (3).

5. Method according to claim 1, further comprising the step of filling the cavity (4) with a second material prior to scaling the cavity.

6. Method according to claim 5, wherein the second material is one or a combination of foam, gel, liquid, gas, beads, wherein the second material preferably comprises silicone.

7. Method according to claim 1, wherein the rigidity of the cushion (1) can be adjusted by varying the thickness and/or structure of the cushion wall(s) (5) along their cross section and/or circumference.

8. Method according to claim 1, wherein the rigidity of the cushion (1) can be adjusted by providing ribs and/or grooves on/within the inner surface of the cushion (1), i.e., the surfaces of the cushion forming the inner cavity walls (5).

9. Method according to claim 1, wherein varying the thickness and/or providing ribs and/or grooves is achieved by varying the thickness of the core (15) and/or by providing structures such as grooves and/or ribs on the surface of the core (15).

10. Method according to claim 1, wherein there are provided two or more horizontal or longitudinal cavities (4) which axe separated by one or more horizontal walls or membranes, and/or there are provided two ore more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

11. Cushion for a respiratory mask manufactured according to the method of claim 1, the cushion comprising a sealed hollow basically ring like structure adapted to fit to over a patient'"'"'s nose and made of a first material, wherein the hollow structure comprises at least one and preferably only one C-shaped cavity (4) extending only along a part of the circumference of the cushion (1).

12. Cushion according to claim 11, wherein the cushion (1) comprises a varying rigidity due to varying the thickness of the cushion wall(s) (5) and/or by providing ribs, grooves and/or further structures on/within the inner surface of the cushion (1), i.e., the surfaces of the cushion forming the inner cavity walls (5).

13. Cushion according to claim 11, wherein the cushion (1) comprises two or more horizontal or longitudinal cavities (4) which are separated by one or more horizontal walls or membranes, and/or there are provided two ore more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

14. Cushion according to claim 11, wherein ratio between width of the cavity and width of the orifice is in the range of about 1/1.5 and 1/2.5, preferably about 1/2, and/or wherein the ratio between the length of the orifice and the height of the cavity lies in the range of about 1/5 to 1/7, preferably about 1/6, particularly for a nasal cushion.

15. Apparatus for manufacturing a cushion (1) for a respiratory mask according to claim 11, comprising at least two mold parts and a C-Shaped core (15) being connected to a handling member being moveable with respect to at least one of the mold parts.