Respiratory mask assembly

• US 8,353,294 B2
• Filed: 03/21/2011
• Issued: 01/15/2013
• Est. Priority Date: 06/16/2004
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Frater, Robert Henry, Drew, Joanne Elizabeth, Kwok, Philip Rodney, McAuliffe, Patrick John, Davidson, Aaron Samuel, Hitchcock, Robin Garth, Gunaratnam, Michael Kassipillai
• Primary Examiner(s): Yu, Justine
• Assistant Examiner(s): SKORUPA, VALERIE LYNN
• Application Number:
  US13/064,349
• Publication Number:
  US 20110220110A1
• Time in Patent Office: 666 Days
• Field of Search: 128/200.24, 128/204.18, 128/203.29, 128/205.25, 128/206.12, 12820621-20713
• US Class Current: 128/207.11
• CPC Class Codes: A61M 16/0057 Pumps therefor
• 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 16/0638 in the form of a pivot
• CPC Class Codes: A61M 16/0644 having the means for adjusting its position
• CPC Class Codes: A61M 16/065 in the form of a pivot
• CPC Class Codes: A61M 16/0655 in the form of a linear or curvilinear slide
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0825 with ball-sockets

Abstract

A cushion for a respiratory mask assembly includes a breathing chamber forming portion and a face contacting portion formed in one piece of an elastomeric material, and a gusset portion including one or more folds. The breathing chamber forming portion includes a mask interior breathing chamber and the face contacting portion is structured to engage a patient'"'"'s face. The gusset portion is structured to provide flexibility to the face contacting portion. The breathing chamber forming portion includes a front side of the mask and the face contacting portion includes a rear side of the mask. The breathing chamber forming portion, when provided to a mask frame, includes an exterior surface exposed at the front side of the mask.

Claims

1. A respiratory mask assembly, comprising:

a frame;

an elbow assembly supported by the frame and adapted to connect to an air delivery conduit;

a cushion provided to the frame, the cushion including;

a face contacting portion comprising an elastomeric material, and a breathing chamber forming portion, and;

at least a portion of the cushion structure to provide flexibility and travel to the face contacting portion,

wherein the frame defines an opening exposing at least a part of an exterior of the breathing chamber forming portion of the cushion; and

a forehead support provided with a forehead cushion that is structured to engage a patient'"'"'s forehead, the forehead support being slidably mounted to an upper portion of the frame to allow linear movement of the forehead support; and

an adjustment mechanism to allow selective adjustment of the forehead support relative to the frame in a plurality of predetermined fixed positions, the adjustment mechanism including an actuator with only a single finger-operated push button associated with at least one tab adapted to be selectively positioned in one of a plurality of slots to positively lock the forehead support relative to the frame in one of the plurality of predetermined fixed positions, the single finger-operated push button being actuatable with a single finger of the patient,

wherein the single finger-operated push button is resiliently urged in a first position in which the forehead support is prevented from moving relative to the upper portion of the frame, and the single finger-operated push button is adapted to be depressed to allow the forehead support to be moved relative to the upper portion of the frame,

wherein the upper portion of the frame includes a support arm and a housing provided to a free end of the support arm, and the forehead support includes a slider that is slidably received within a receiving space defined by the housing to move between an extended position and a retracted position, the slider including a free end that is enclosed by the housing throughout movement between the extended position and the retracted position,

wherein the housing includes a front side and a rear side, the receiving space extending from the rear side of the housing, and the front side of the housing includes a closed configuration,

wherein the forehead support is slidably mounted for horizontal, linear movement which is substantially perpendicular to a longitudinal axis of the support arm,

wherein the forehead support includes a stop to at least stop the forehead support in a fully extended position with the respect to the frame,

wherein the single finger-operated push button includes a portion that extends through an opening provided in a top side of the housing, and

wherein the single finger-operated push button is adapted to be depressed in a direction which is substantially parallel to the support arm.

2. A respiratory mask assembly according to claim 1, further comprising plurality of vents to washout CO₂ from a breathing chamber of the cushion.

3. A respiratory mask assembly according to claim 2, wherein the plurality of vents includes at least four vents.

4. A respiratory mask assembly according to claim 1, wherein the cushion is a full-face cushion.

5. A respiratory mask assembly according to claim 1, wherein a portion of the cushion is provided within a mask retaining portion of the frame such that the face contacting portion is provided on a first side of the mask retaining portion.

6. A respiratory mask assembly according to claim 5, wherein the at least a portion of the cushion is provided between the breathing chamber forming portion and the face contacting portion, and the at least a portion of the cushion is provided on the first side of the mask retaining portion adjacent the face contacting portion.

7. A respiratory mask assembly according to claim 6, further comprising upper slotted connector structures provided on the forehead support adapted to engage upper headgear straps of headgear and lower slotted clip structures provided on the frame adapted to engage lower headgear straps of headgear.

8. A respiratory mask assembly according to claim 7, wherein the elbow assembly is a swivel elbow assembly.

9. A respiratory mask assembly according to claim 1, wherein the frame includes a mask retaining portion that at least partly encloses or wraps around the cushion.

10. A respiratory mask assembly according to claim 9, wherein the mask retaining portion includes an inwardly facing retaining surface that engages an outwardly facing surface of the cushion.

11. A respiratory mask assembly according to claim 1, wherein the single finger-operated push button is adapted to be depressed in a substantially vertical direction which is substantially parallel to the longitudinal axis of the support arm that extends from a connection point to the frame to the housing.

12. A respiratory mask assembly according to claim 1, wherein the at least a portion of the cushion includes a side wall pre-formed at an angle to encourage buckling outwards or inwards upon donning of the mask assembly and/or application of headgear strap tension.

13. A respiratory mask assembly according to claim 1, wherein the at least a portion of the cushion includes a side wall pre-formed at an angle to encourage flexing or bending in response to a force that is generated due to contact of the face contacting portion with the patient'"'"'s face and application of headgear strap tension to maintain a seal between the face contacting portion and the patient'"'"'s face.

14. A respiratory mask assembly according to claim 1, wherein the cushion includes:

(i) a non-face contacting portion connected to or otherwise provided to the frame, made of a resilient material that maintains its general shape and structured to provide some degree of spring effect for comfort and seal upon donning of the mask assembly and/or applying headgear strap tension, the non-face contacting portion extending outwardly away from the frame; and

(ii) a face-contacting membrane of the face contacting portion spaced apart from an underlying rim.

15. A respiratory mask assembly according to claim 1, wherein the stop is provided by an extension provided to the slider that is structured to engage a first stop portion of the housing to stop the forehead support in the fully extended position.

16. A respiratory mask assembly according to claim 15, further comprising a second stop to stop the forehead support in a fully retracted position with respect to the frame.

17. A respiratory mask assembly according to claim 16, wherein the second stop is provided by (1) the extension that is structured to engage a second stop portion of the housing to stop the forehead support in the fully retracted position and/or (2) the forehead support engaging a rear side of the housing.

18. A respiratory mask assembly according to claim 1, wherein the cushion includes a non-face contacting portion oriented towards the frame and the face contacting portion that is adapted to contact with a portion of the patient'"'"'s face, the face contacting portion including a membrane spaced above an underlying rim, and the at least a portion of the cushion is provided between the non-face contacting and face contacting portions and provides a portion that extends inwardly from the face contacting portion towards a breathing chamber of the cushion.

19. A respiratory mask assembly according to claim 1, wherein the forehead cushion is mounted to the forehead support for movement in two or more planes.

20. A respiratory mask assembly according to claim 1, wherein the forehead cushion is mounted to the forehead support such that movement of the forehead support is decoupled from application of forces to the patient.

21. A respiratory mask assembly according to claim 1, wherein the forehead cushion includes a concave surface adapted to contact the patient'"'"'s forehead.

22. A respiratory mask assembly according to claim 1, wherein the forehead cushion includes a single cushion including two attachment points to the forehead support and adapted to extend across the patient'"'"'s forehead.

23. A respiratory mask assembly according to claim 1, wherein the at least a portion of the cushion includes at least one fold.

24. A respiratory mask assembly according to claim 1, wherein the at least a portion of the cushion includes an inverted portion.

25. A respiratory mask assembly according to claim 24, wherein the inverted portion extends inwardly towards a breathing chamber of the cushion, the inverted portion defining a spring structure.

26. A respiratory mask assembly according to claim 25, wherein the face-contacting portion includes a membrane spaced above an underlying rim, and the membrane and underlying rim are supported by the inverted portion.

27. A respiratory mask assembly according to claim 26, wherein the inverted portion includes a first portion extending inwardly from a non-face contacting portion of the cushion to an interior tip portion and a second portion extending outwardly from the interior tip portion away from the breathing chamber to a base of the face contacting portion, both the membrane and the underlying rim being mounted proximate an outer edge of the second portion.

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

a frame having an extended support arm with a housing provided on a free end of the support arm;

a mask assembly cushion associated with the frame;

a forehead support provided with a slider that is slidably received within a receiving space defined by the housing to move between extended and retracted positions, the slider being equipped with a forehead cushion that is structured to engage a patient'"'"'s forehead;

a headgear assembly removably attached to the frame and forehead support to maintain the mask assembly cushion in a desired adjusted position on the patient'"'"'s face, the headgear assembly including a pair of upper straps and a pair of lower straps with the upper straps removably connected to slotted connector structures provided on the forehead support and the lower straps removably connected to slotted clip structures provided on the frame;

a swivel elbow assembly attached to a front portion of the frame, the swivel elbow assembly adapted to be connected to a conduit that is connected to a pressurized supply that supplies pressurized breathable gas through the conduit and elbow assembly and into a breathing chamber defined by the mask assembly cushion for breathing by the patient; and

an adjustment mechanism to allow selective adjustment of the forehead support relative to the housing in a plurality of predetermined fixed positions, the adjustment mechanism including an actuator with only a single finger-operated push button to releasably lock the forehead support relative to the housing in one of the plurality of predetermined fixed positions, the single finger-operated push button being resiliently urged in a lock position in which the forehead support is prevented from moving within the housing, and the single finger-operated push button is adapted to be depressed, with a single finger of the patient, to release the forehead support and allow linear movement of the forehead support in a direction substantially perpendicular to a longitudinal axis of the support arm,

wherein the housing includes a front side and a rear side, the receiving space extending from the rear side of the housing, and the front side of the housing includes a closed configuration such that a free end of the slider is enclosed by the housing throughout movement between the extended and retracted positions,

wherein the single finger-operated push button includes a portion that extends through an opening provided in a top side of the housing, and

wherein the single finger-operated push button is adapted to be depressed in a direction which is substantially parallel to the support arm.

29. A respiratory mask assembly according to claim 28, wherein the single finger-operated push button is adapted to be depressed in a substantially vertical direction which is substantially parallel to the longitudinal axis of the support arm that extends from a connection point to the frame to the housing.

30. A respiratory mask assembly according to claim 28, wherein the forehead support is linearly movable in only a single dimension, in and between the plurality of predetermined fixed positions, and is not pivotable, rotatable, or otherwise movable to change an angular attitude of the forehead support.

31. A respiratory mask assembly according to claim 28, wherein the actuator with only a single finger-operated push button is associated with at least one tab adapted to be selectively positioned in one of a plurality of slots.

32. A respiratory mask assembly according to claim 31, wherein the plurality of slots includes four slots.

33. A respiratory mask assembly according to claim 31, wherein the actuator with only a single finger-operated push button is associated with a plurality of tabs.

34. A respiratory mask assembly according to claim 28, wherein the forehead support includes a pair of extensions that are positioned within slots provided on the housing to support and guide the forehead support.

35. A respiratory mask assembly according to claim 34, wherein the extensions are provided to opposing sides of the slider.

36. A respiratory mask assembly according to claim 28, wherein the support arm and housing are generally L-shaped, the support arm providing a vertically extending leg and the housing providing a horizontally extending leg that is transverse to the support arm.

37. A respiratory mask assembly according to claim 28, wherein the single finger-operated push button is adapted to be depressed in a generally vertical direction which is generally transverse to a direction of movement of the forehead support.

38. A respiratory mask assembly according to claim 28, wherein the slider includes a pair of supports received in respective guide slots provided to the receiving space of the housing to guide the slider between extended and retracted positions with respect to the housing.

39. A respiratory mask assembly according to claim 28, wherein the slider and the receiving space include complementary non-round shapes.

40. A respiratory mask assembly according to claim 28, wherein an exterior of the housing includes a generally rectangular shape.

41. A respiratory mask assembly according to claim 28, wherein the mask assembly is a full-face mask structured to deliver breathable gas to the patient'"'"'s nose and mouth.

42. A respiratory mask assembly according to claim 28, wherein the mask assembly cushion includes a non-face contacting portion oriented towards the frame and a face contacting portion adapted to contact with a portion of the patient'"'"'s face, the face contacting portion including a membrane spaced above an underlying rim.

43. A respiratory mask assembly according to claim 42, wherein the face contacting portion is provided to a connecting structure that forms a transition between the face contacting portion and the frame and provides a spring-like effect.

44. A respiratory mask assembly according to claim 42, wherein the mask assembly cushion includes a central portion between the non-face contacting portion and the membrane, the central portion including an inverted portion that extends inwardly the breathing chamber of the mask assembly cushion, the inverted portion including a spring structure.

45. A respiratory mask assembly according to claim 28, wherein the mask assembly cushion includes a breathing chamber forming portion and a face contacting portion, the breathing chamber forming portion including the breathing chamber and the face contacting portion structured to engage a patient'"'"'s face.

46. A respiratory mask assembly according to claim 28, wherein the frame has a front side and a rear side, and the front side of the frame defines an opening through which at least part of the mask assembly cushion is exposed.

47. A respiratory mask assembly according to claim 28, wherein at least a portion of the mask assembly cushion extends beyond a perimeter of the frame.

48. A respiratory mask assembly according to claim 28, wherein the forehead cushion defines a chamber.

49. A respiratory mask assembly according to claim 28, wherein the forehead cushion includes a pair of shank portions adapted to be received within respective openings provided in the forehead support to attach the forehead cushion to the forehead support.

50. A respiratory mask assembly according to claim 28, further comprising a vent cover provided to the swivel elbow assembly to vent air.

51. A respiratory mask assembly according to claim 28, wherein the mask assembly cushion includes a side wall pre-formed at an angle to encourage buckling outwards or inwards upon donning of the mask assembly and/or application of headgear strap tension to maintain a seal between a face contacting portion of the cushion and the patient'"'"'s face.

52. A respiratory mask assembly according to claim 28, wherein the mask assembly cushion includes a side wall pre-formed at an angle to encourage flexing or bending in response to a force that is generated due to contact of a face contacting portion of the mask assembly cushion with the patient'"'"'s face and application of headgear strap tension to maintain a seal between the face contacting portion and the patient'"'"'s face.

53. A respiratory mask assembly according to claim 28, wherein the mask assembly cushion includes:

(i) a non-face contacting portion connected to or otherwise provided to the frame, made of a resilient material that maintains its general shape but will provide some degree of spring effect for comfort and seal upon donning of the mask assembly and/or application of headgear strap tension, the non-face contacting portion extending outwardly away from the frame; and

(ii) a face-contacting membrane of a face contacting portion of the mask assembly cushion spaced apart from an underlying rim.

54. A respiratory mask assembly according to claim 28, wherein the forehead support is slidably mounted for horizontal, linear movement.

55. A respiratory mask assembly according to claim 28, wherein the forehead support includes a stop to at least stop the forehead support in a fully extended position with respect to the frame.

56. A respiratory mask assembly according to claim 28, wherein the slider includes an exterior surface that slides relative to an interior surface of the receiving space defined by the housing.

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

a frame;

a facial cushion engaged with the frame;

a forehead support provided with a forehead cushion that is structured to engage a patient'"'"'s forehead, the forehead support being slidably mounted to the frame to allow linear movement of the forehead support; and

an adjustment mechanism to allow selective adjustment of the forehead support relative to the frame in a plurality of predetermined fixed positions, the adjustment mechanism including an actuator with only a single finger-operated push button associated with at least one tab adapted to be selectively positioned in one of a plurality of slots to positively lock the forehead support relative to the frame in one of the plurality of predetermined fixed positions, the single finger-operated push button being actuatable with a single finger of the patient,

wherein the single finger-operated push button is resiliently urged in a first position in which the forehead support is prevented from moving relative to the upper portion of the frame, and the single finger-operated push button is adapted to be depressed to allow the forehead support to be moved relative to the upper portion of the frame,

wherein the frame includes a main body, a support arm extending substantially vertically upwards from the main body, and a housing provided to a free end of the support arm, and the forehead support includes a slider that is slidably received within a receiving space located inside the housing to move between extended and retracted positions, the slider including a free end that is enclosed by the housing throughout movement between the extended and retracted positions,

wherein the forehead support is slidably mounted for linear, substantially horizontal movement which is substantially perpendicular to the substantially vertically extending support arm,

wherein the forehead support includes a stop to at least stop the forehead support in a fully extended position with respect to the frame, and

wherein the single finger-operated push button includes a portion that extends through an upwardly facing opening provided in the housing,

wherein the housing includes a forwardly facing side and a rearwardly facing side, the receiving space extending from the rearwardly facing side of the housing, and the forwardly facing side of the housing includes a closed configuration,

wherein the single finger-operated push button is adapted to be depressed in a substantially vertically downwards direction which is substantially parallel to the vertically extending support arm.

58. A respiratory mask assembly according to claim 57, wherein the forehead support is linearly movable in only a single dimension, in and between the plurality of predetermined fixed positions, and is not pivotable, rotatable, or otherwise movable to change an angular attitude of the forehead support.

59. A respiratory mask assembly according to claim 58, wherein the slider and the receiving space inside the housing include complementary non-round shapes.

60. A respiratory mask assembly according to claim 59, wherein an exterior of the housing includes a generally rectangular shape.

61. A respiratory mask assembly according to claim 60, wherein the plurality of slots includes four slots.

62. A respiratory mask assembly according to claim 61, wherein the single finger-operated push button is associated with a plurality of tabs.

63. A respiratory mask assembly according to claim 62, wherein the facial cushion includes a side wall pre-formed at an angle to encourage buckling outwards or inwards upon donning of the mask assembly and/or application of headgear strap tension to maintain a seal between a face contacting portion of the facial cushion and the patient'"'"'s face.

64. A respiratory mask assembly according to claim 62, wherein the facial cushion includes a side wall pre-formed at an angle to encourage flexing or bending in response to a force that is generated due to contact of a face contacting portion of the facial cushion with the patient'"'"'s face and application of headgear strap tension to maintain a seal between the face contacting portion and the patient'"'"'s face.

65. A respiratory mask assembly according to claim 62, wherein the facial cushion includes:

(i) a non-face contacting portion connected to or otherwise provided to the frame, made of a resilient material that maintains its general shape and structured to provide some degree of spring effect for comfort and seal upon donning of the mask assembly and/or applying headgear strap tension, the non-face contacting portion extending outwardly away from the frame; and

(ii) a face-contacting membrane of a face contacting portion of the facial cushion spaced apart from an underlying rim.

66. A respiratory mask assembly according to claim 62, wherein the stop is provided by an extension provided to the slider that is structured to engage a first stop portion of the housing to stop the forehead support in the fully extended position.

67. A respiratory mask assembly according to claim 66, further comprising a second stop to stop the forehead support in a fully retracted position with respect to the frame.

68. A respiratory mask assembly according to claim 67, wherein the second stop is provided by (1) the extension that is structured to engage a second stop portion of the housing to stop the forehead support in the fully retracted position and/or (2) the forehead support engaging a rear side of the housing.

69. A respiratory mask assembly according to claim 62, wherein the facial cushion includes a non-face contacting portion oriented towards the frame and a face contacting portion that is adapted to contact with a portion of the patient'"'"'s face, the face contacting portion including a membrane spaced above an underlying rim, and an inverted portion is provided between the non-face contacting and face contacting portions and provides a portion that extends inwardly from the face contacting portion towards a breathing chamber of the facial cushion.

70. A respiratory mask assembly according to claim 69, wherein the mask assembly is a full-face mask structured to deliver breathable gas to the patient'"'"'s nose and mouth.

71. A respiratory mask assembly according to claim 62, wherein the facial cushion includes a non-face contacting portion oriented towards the frame and a face contacting portion adapted to contact with a portion of the patient'"'"'s face, the face contacting portion including a membrane spaced above an underlying rim.

72. A respiratory mask assembly according to claim 57, wherein the frame has a front side and a rear side, and the front side of the frame defines an opening through which at least part of the facial cushion is exposed.