HOLLOW STRUCTURE FOR RESPIRATORY MASK CUSHION

• US 20140044905A1
• Filed: 08/09/2013
• Published: 02/13/2014
• Est. Priority Date: 08/10/2012
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed R&D Germany GmbH (ResMed Incorporated)
• Inventors: NICKOL, Johannes, ROTHFUSS, Jens, BURZ, Sebastian, EIBL, Robert, LANG, Bernd
• Granted Patent: US 9,642,977 B2
• Time in Patent Office: Days
• US Class Current: 428/35.7
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• CPC Class Codes: A61M 16/0605 Means for improving the adaptation of the mask to the patient
• 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: B29D 22/00 Producing hollow articles tubular articles B29D23/00; pneumatic tyres B29D30/00
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]

Abstract

The present invention provides a method for producing a filled hollow structure, preferably a cushion for a breathing mask. According to said method, a hollow structure of a first material having a cavity is produced, wherein the hollow structure has an inlet to and an outlet from the cavity. The hollow structure is positioned on a tool for holding the hollow structure. Subsequently a second material is inserted through the inlet into the cavity, while gas present in the cavity can escape through the outlet. Finally, the inlet and/or the outlet is sealed. During the step of inserting the second material through the inlet into the cavity the outlet resists flow of said second material.

Claims

1. Method for producing a filled hollow structure, comprising the steps of:

a) producing a hollow structure (1) of a first material, preferably of silicone, having a cavity (2), the hollow structure (1) having an inlet (3) to and an outlet (4) from the cavity (2);

b) positioning the hollow structure (1) on a tool for holding the hollow structure;

c) inserting a second material through the inlet (3) into the cavity (2), while gas present in the cavity (2) can escape through the outlet (4); and

d) sealing the inlet (3) and/or the outlet (4);

wherein the outlet (4) resists, preferably prevents, flow of the second material during insertion into the cavity (2).

2. Method according to any one of the preceding claims, wherein the inlet and/or outlet comprises a membrane (5), which is adapted to be punctured.

3. Method according to claim 2, further comprising the step of puncturing the membrane (5) before inserting the second material through the inlet (3).

4. Method according to claim 2, wherein the membrane (5) comprises a predetermined breaking point (6), preferably a crossed slot, a cross recess, a weakened region or a perforation.

5. Method according to claim 1, wherein the inlet (3) and/or outlet (4) comprises a membrane (5), which has an orifice, preferably in the shape of a crossed slot.

6. Method according to claim 2, wherein the (punctured) membrane (5) allows for venting, yet resists, preferably prevents, flow of the second material during insertion into the cavity.

7. Method according to claim 2, wherein the (punctured) membrane (5) prevents flow of the second material if exposed to a pressure up to 3 hPa, preferably up to 5 hPa.

8. Method according to claim 2, wherein the (punctured) membrane (5) prevents flow of a material having a viscosity in a range between 50 and 2000 MPas, preferably between 100 and 1100 MPas, at 25°

C. (DIN EN ISO

     3219) if exposed to a pressure up to 3 hPa, preferably up to 5 hPa.

9. Method according to claim 2, wherein the flow rate of a material having a viscosity in a range between 50 and 2000 MPas, preferably between 100 and 1100 MPas, at 25°

C. (DIN EN ISO

     3219) if exposed to a pressure up to 3 hPa, preferably up to 5 hPa, through the (punctured) membrane is smaller than 100 mm³/s, preferably smaller than 10 mm³/s

10. Method according to claim 2, wherein the membrane (5) has a diameter of less than 5 mm, preferably of less than 4 mm, more preferably of less than 3 mm.

11. Method according to claim 2, wherein the orifice of the membrane (5) or the opening in the membrane (5) created by puncturing the membrane has a diameter of less than 4 mm, preferably of less than 3 mm, more preferably of less than 2 mm.

12. Method according to claim 1, wherein the second material has a viscosity in a range between 50 and 2000 MPas, preferably between 100 and 1100 MPas at 25°

C. (DIN EN ISO

     3219).

13. Method according to claim 1, wherein the inserted material is distributed within the cavity by means of gravity, preferably by means of gravity only.

14. Method according to claim 1, wherein the hollow structure is pivoted or tilted during inserting the second material in order to completely fill the cavity with the second material.

15. Method according to claim 1, further comprising the step of sealing the inlet (3) and/or outlet (4) by curing and/or hardening the second material.

16. Method according to claim 1, further comprising the step of sealing the inlet (3) and/or outlet (4) by applying a sealing material, preferably one or a combination of silicone, polyurethane and thermoplastic elastomers.

17. Method according to claim 1, wherein the first material consists of or comprises one or a combination of silicone, polysiloxane, silicone foam, silicone rubber and thermoplastic polymers.

18. Method according to claim 1, wherein the second material consists of or comprises one or a combination of gel, foam, liquid, gas, beads and silicone.

19. Method according to claim 1, wherein the shore hardness of the second material lies in a range between 10 and 20, preferably between 12 and 18, and most preferably between 14 and 16 shore 000, preferably according to DIN 53505.

20. Method according to claim 1, further comprising the step of removing the hollow structure from the tool, preferably by using compressed air.

21. Method according to claim 1, wherein the second material is inserted into the cavity under pressure and/or vacuum.

22. Method according to claim 1, wherein the hollow structure is a cushion for a breathing mask.

23. Hollow structure (1) made of a first material having a cavity (2), the structure comprising an inlet (3) for inserting a second material into the cavity (2) and an outlet (4) for gas present in the cavity (2) to escape, wherein the inlet (3) and/or outlet (4) comprises a membrane (5), which is adapted to be punctured and/or which has an orifice.

24. Hollow structure according to claim 23, wherein the punctured membrane (5) and/or the orifice has a structure adapted to bias the membrane (5) to a closed position.

25. Hollow structure according to claim 23, wherein the orifice has the shape of a crossed slot.

26. Hollow structure according to claim 23, wherein the membrane comprises a predetermined breaking point (6), preferably a crossed slot, a cross recess, a weakened region or a perforation.

27. Hollow structure according to claim 23, wherein the punctured membrane (5) and/or the orifice of the membrane (5) allows for venting, yet resists, preferably prevents, flow of a material having a viscosity in a range between 50 and 2000 MPas, preferably between 100 and 1100 MPas, at 25°

C. (DIN EN ISO

     3219) if exposed to a pressure up to 3 hPa, preferably up to 5 hPa.

28. Hollow structure according to claim 23, wherein the flow rate of a material having a viscosity in a range between 50 and 2000 MPas, preferably between 100 and 1100 MPas, at 25°

C. (DIN EN ISO

     3219) if exposed to a pressure up to 3 hPa, preferably up to 5 hPa, through the (punctured) membrane is smaller than 100 mm³/s, preferably smaller than 10 mm³/s

29. Hollow structure according to claim 23, wherein the membrane (5) has a diameter of less than 5 mm, preferably of less than 4 mm, more preferably of less than 3 mm.

30. Hollow structure according to claim 23, wherein the orifice of the membrane (5) or the opening in the membrane (5) created by puncturing the membrane has a diameter of less than 4 mm, preferably of less than 3 mm, more preferably of less than 2 mm.

37. Hollow structure according to claim 23, wherein the self-healing membrane comprises a predetermined breaking point (6), preferably a crossed slot, a cross recess, a weakened region or a perforation.

38. Cushion for a respiratory mask comprising a hollow structure (1) according to claim 23, wherein the cavity (2) is filled with the second material.

31. Hollow structure (1) made of a first material having a cavity (2), the structure comprising an inlet (3) for inserting a second material into the cavity (2) and an outlet (4) for gas present in the cavity (2) to escape, wherein the inlet (3) and/or outlet (4) comprises a self-healing membrane (5).

32. Hollow structure according to claim 31, wherein the self-healing membrane is adapted to be punctured by a puncturing tool in such a manner as to allow for the puncture site to self-seal upon removal of the puncturing tool.

33. Hollow structure according to claim 31, wherein the self-healing membrane is adapted to be punctured in such a manner as to allow for the puncture site to self-seal upon insertion of the second material into the cavity.

34. Hollow structure according to claim 31, wherein the self-healing membrane has an orifice which is adapted to self-seal upon insertion of the second material into the cavity.

35. Hollow structure according to claim 32, wherein the punctured membrane (5) and/or the orifice has a structure adapted to bias the membrane (5) to a closed position.

36. Hollow structure according to claim 34, wherein the orifice has the shape of a crossed slot.