Cushion for patient interface

• US 8,485,192 B2
• Filed: 06/29/2012
• Issued: 07/16/2013
• 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, Eves, Matthew, Worboys, David John, Lynch, Susan Robyn
• Primary Examiner(s): Yu, Justine
• Assistant Examiner(s): Louis, LaToya M
• Application Number:
  US13/537,876
• Publication Number:
  US 20120266886A1
• Time in Patent Office: 382 Days
• Field of Search: 128/202.25, 12820621-20626, 128/206.28, 128/207.13
• 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: 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 cushion extending in a direction away from the base wall and 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 nasal bridge region, a pair of cheek regions, and a chin region adapted to form a continuous seal on the patient'"'"'s nasal bridge region, pair of cheek regions, and chin region, respectively,

a spring-like structure configured to, at least in part, define displacement of the cushion with respect to a force applied from the frame,

wherein the cushion is a full-face cushion and includes a nasal bridge region, a pair of cheek regions and a chin region,

wherein the underlying cushion includes a nasal bridge region and a pair of cheek regions, and

wherein the underlying cushion is absent in at least a portion of the chin region of the cushion such that the cushion has a single-walled construction formed by the membrane in the chin region of the cushion.

2. The cushion according to claim 1, wherein the membrane includes five distinct regions, and a configuration of the spring-like structure varies in at least three of the five distinct regions.

3. The cushion according to claim 1, wherein a configuration of the spring-like structure varies along a length of the seal.

4. The cushion according to claim 1, wherein the underlying cushion is continuous along the nasal bridge region and the pair of cheek regions of the underlying cushion.

5. The cushion according to claim 1, wherein the underlying cushion is dimensioned to allow substantially the entire chin region of the membrane to readily flex in the chin region of the full-face cushion.

6. The cushion according to claim 1, wherein the underlying cushion and the membrane comprise a one-piece structure.

7. The cushion according to claim 6, wherein the absence of the underlying cushion in the at least a portion of the chin region of the cushion allows the chin region of the membrane to flex in the chin region of the cushion.

8. The cushion according to claim 7, wherein the underlying cushion and the membrane form at least a double-walled construction at least in the pair of cheek regions of the cushion, said at least double-walled construction being configured such that the underlying cushion is positioned to restrain movement of the membrane.

9. The cushion according to claim 8, wherein the membrane or the underlying cushion forms a widest point of the cushion, and a bottom portion of the base wall is internally offset with respect to the widest point.

10. The cushion according to claim 9, wherein the base wall and the underlying cushion form a support structure, a first cross-sectional configuration of the support structure in the nasal bridge region of the cushion is different than a second cross-sectional configuration of the support structure in the pair of cheek regions of the cushion, and the first and second cross-sectional configurations of the support structure in the nasal bridge region and the pair of cheek regions vary by varying an underlying cushion offset relative to the base wall.

11. The cushion according to claim 10, wherein:

a first portion of the support structure extends laterally beyond a second exterior portion of the cushion,

the first portion of the support structure is movable with respect to the second exterior portion of the cushion when the cushion is worn and the force is exerted on the cushion,

the first portion of the support structure is movable from an initial position towards a space exterior of the cushion when the force is exerted on the cushion, and

the first portion of the support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the cushion.

12. The cushion according to claim 10, wherein:

a first portion of the support structure extends laterally beyond a second exterior portion of the cushion,

the first portion of the support structure, in the pair of cheek regions of the cushion, is movable with respect to the second exterior portion of the cushion when the cushion is worn and the force is exerted on the cushion,

when the force is exerted on the cushion, the first portion of the support structure, in the pair of cheek regions of the cushion, moves from an initial position toward a space exterior of the breathing cavity and the chin region of the membrane readily flexes toward a breathing cavity defined at least in part by the cushion, and

the first portion of the support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the cushion.

13. The cushion according to claim 1, wherein the underlying cushion is continuous along the nasal bridge region and the pair of cheek regions of the underlying cushion and terminates proximate a transition between the chin region of the cushion and a respective cheek region of the cushion.

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

a base wall;

an underlying cushion extending in a direction away from the base wall and 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 nasal bridge region, a pair of cheek regions, and a chin region adapted to form a continuous seal on the patient'"'"'s nasal bridge region, pair of cheek regions, and chin region, respectively,

wherein the membrane or 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,

wherein the cushion is a full-face cushion and includes a nasal bridge region, a pair of cheek regions and a chin region, the cushion defining, at least in part, a breathing cavity, and

wherein the underlying cushion includes a nasal bridge region and a pair of cheek regions to form a support for the membrane, the underlying cushion being continuous along the nasal bridge region and the pair of cheek regions of the underlying cushion, the underlying cushion being absent in a majority of the chin region of the full-face cushion so as to allow substantially the entire chin region of the membrane to flex toward the breathing cavity without restraint due to the underlying cushion.

15. The cushion according to claim 14, 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.

16. The cushion according to claim 14, wherein the underlying cushion and the membrane comprise a one-piece structure.

17. The cushion according to claim 14, further comprising a spring configuration that defines displacement of the cushion with respect to a force applied from a frame.

18. The cushion according to claim 14, wherein the pair of cheek regions of the underlying cushion are positioned to restrain movement of the membrane.

19. The cushion according to claim 14, wherein the membrane or the underlying cushion forms a widest point of the cushion, and a bottom portion of the base wall is internally offset with respect to the widest point.

20. The cushion according to claim 14, wherein the underlying cushion allows the entire chin region of the membrane to flex without restraint due to the underlying cushion.

21. A full-face cushion for a patient interface that delivers breathable gas to a patient, the full-face cushion including a nasal bridge, a pair of cheek regions, and a chin region, the full-face cushion defining, at least in part, a breathing cavity, the full-face cushion comprising:

an underlying cushion including a nasal bridge region, a left cheek region and a right cheek region; and

a membrane including a nasal bridge region, a pair of cheek regions, and a chin region to form a continuous seal on the patient'"'"'s face, the membrane having an inner edge delimiting an aperture adapted to receive the patient'"'"'s nose and mouth,

wherein the underlying cushion is continuous along the left cheek region, the nasal bridge region and the right cheek region of the underlying cushion,

wherein the underlying cushion includes an underlying cushion cutaway profile in the chin region of the cushion, the underlying cushion cutaway profile having a width that is substantially the same as but less than a mouth width of the aperture to allow the chin region of the membrane to flex toward the breathing cavity without restraint from the underlying cushion due to the underlying cushion cutaway profile, and

wherein the underlying cushion is absent in the entire underlying cushion cutaway profile.

22. The full-face cushion according to claim 21, wherein the left cheek region and the right cheek region of the underlying cushion are positioned to restrain movement of the membrane.

23. The full-face cushion according to claim 21, further comprising a spring-like structure configured to, at least in part, define displacement of the full-face cushion with respect to a force applied from a frame.

24. The full-face cushion according to claim 21, wherein the underlying cushion and the membrane comprise a one-piece structure.

25. The full-face cushion according to claim 21, further comprising a wall to which the underlying cushion is connected, wherein the membrane or the underlying cushion forms a widest point of the cushion, and a bottom portion of the wall is internally offset with respect to the widest point.

26. The full-face cushion according to claim 25, wherein the wall and the underlying cushion form a support structure, a first cross-sectional configuration of the support structure in the nasal bridge region of the cushion is different than a second cross-sectional configuration of the support structure in the cheek regions of the cushion, and the first and second cross-sectional configurations of the support structure in the nasal bridge region and the cheek regions vary by varying an underlying cushion offset relative to the wall.

27. The full-face cushion according to claim 26, wherein:

a first portion of the support structure extends laterally beyond a second exterior portion of the cushion,

the first portion of the support structure is movable with respect to the second exterior portion of the cushion when the cushion is worn and a force is exerted on the cushion,

the first portion of the support structure is movable from an initial position towards a space exterior of the cushion when the force is exerted on the cushion, and

the first portion of the support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the cushion.

28. The full-face cushion according to claim 26, wherein:

a first portion of the support structure extends laterally beyond a second exterior portion of the cushion,

the first portion of the support structure, in the cheek regions of the cushion, is movable with respect to the second exterior portion of the cushion when the cushion is worn and a force is exerted on the cushion,

when the force is exerted on the cushion, the first portion of the support structure, in the cheek regions of the cushion, moves from an initial position toward a space exterior of the breathing cavity and the chin region of the membrane readily flexes toward the breathing cavity, and

the first portion of the support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the cushion.

29. The full-face cushion according to claim 21, wherein the mouth width is at a widest point of the aperture.

30. The full-face cushion according to claim 29, wherein the mouth width is about 60 mm±

5.

31. The full-face cushion according to claim 30, wherein the width of the underlying cushion cutaway profile is about 58 mm±

5.

32. The full-face cushion according to claim 31, wherein the mouth width is 60 mm±

5.

33. The full-face cushion according to claim 31, wherein the width of the underlying cushion cutaway profile is 58 mm±

5.

34. The full-face cushion according to claim 21, wherein the underlying cushion is discontinuous due to the underlying cushion cutaway profile.

35. A cushion for a patient interface that delivers breathable gas to a patient, the cushion including a nasal bridge region, a pair of cheek regions and a chin region, the cushion defining, at least in part, a breathing cavity, the cushion comprising:

a membrane including a nasal bridge region, a pair of cheek regions and a chin region to form a continuous seal on the patient'"'"'s face, the membrane having an inner edge delimiting an aperture that is adapted to receive the patient'"'"'s nose and mouth, the aperture including a lower portion having a mouth width that is about 60 mm±

5; and

an underlying cushion including a nasal bridge region, a left cheek region and a right cheek region,

wherein the membrane, from front view, covers the underlying cushion,

wherein the left cheek region and the right cheek region of the underlying cushion extend adjacent a perimeter of the cushion so as to form at least a double-walled construction with the membrane in the cheek regions of the cushion,

wherein the underlying cushion includes an underlying cushion cutaway profile in the chin region of the cushion, the underlying cushion cutaway profile having a width that is about 58 mm±

5 to allow substantially the entire chin region of the membrane to flex toward the breathing cavity without restraint due to the underlying cushion,

wherein the mouth width is at a widest point of the aperture and the width of the underlying cushion cutaway profile is less than the mouth width, and

wherein the underlying cushion is absent in the entire underlying cushion cutaway profile.

36. The cushion according to claim 35, wherein the left cheek region and the right cheek region of the underlying cushion are positioned to restrain movement of the membrane.

37. The cushion according to claim 36, wherein the underlying cushion and the membrane comprise a one-piece structure.

38. The cushion according to claim 37, further comprising a wall to which the underlying cushion is connected, wherein the membrane or the underlying cushion forms a widest point of the cushion, and a bottom portion of the wall is internally offset with respect to the widest point.

39. The cushion according to claim 38, wherein the underlying cushion is continuous along the left cheek region, the nasal bridge region and the right cheek region of the underlying cushion.

40. The cushion according to claim 39, wherein the wall and the underlying cushion form a support structure, a first cross-sectional configuration of the support structure in the nasal bridge region of the cushion is different than a second cross-sectional configuration of the support structure in the cheek regions of the cushion, and the first and second cross-sectional configurations of the support structure in the nasal bridge region and the cheek regions vary by varying an underlying cushion offset relative to the wall.

41. The cushion according to claim 40, wherein:

a first portion of the support structure extends laterally beyond a second exterior portion of the cushion,

the first portion of the support structure, in the cheek regions of the cushion, is movable with respect to the second exterior portion of the cushion when the cushion is worn and a force is exerted on the cushion,

when the force is exerted on the cushion, the first portion of the support structure, in the cheek regions of the cushion, moves from an initial position toward a space exterior of the breathing cavity and the chin region of the membrane readily flexes toward the breathing cavity, and

the first portion of the support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the cushion.

42. The cushion according to claim 35, wherein the underlying cushion includes only a nasal bridge region, a left cheek region and a right cheek region.

43. The cushion according to claim 35, wherein, in response to a force exerted on the cushion when the cushion is worn, the cushion is relatively flexible in the chin region and an upper portion of the cheek regions of the cushion, and relatively stiff in a lower portion of the cheek regions of the cushion.

44. The cushion according to claim 35, wherein the underlying cushion includes a pair of opposing ends which define the underlying cushion cutaway profile.

45. The cushion according to claim 44, wherein, in a bottom view, each of the opposing ends of the underlying cushion forms an angle relative to a lower portion of the cushion.

46. The cushion according to claim 35, wherein the mouth width is 60 mm±

5.

47. The cushion according to claim 35, wherein the width of the underlying cushion cutaway profile is 58 mm±

5.