Cushion for patient interface

• US 8,550,083 B2
• Filed: 11/29/2012
• Issued: 10/08/2013
• 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:
  US13/689,211
• Publication Number:
  US 20130087149A1
• Time in Patent Office: 313 Days
• Field of Search: 128/205.25, 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 method of selecting a cushion from a series of full-face cushions to deliver breathable gas to a patient via a mask system for treatment of Obstructive Sleep Apnea with Non-Invasive Positive Pressure Ventilation, the method comprising:

providing a series of full-face cushions, each of the full-face cushions including a nasal bridge region, cheek regions and a chin region, each of the full-face cushions defining, at least in part, a breathing cavity, the series comprising;

a first full-face cushion, the first full-face cushion comprising a first membrane including a first nasal bridge region, first cheek regions and a first chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the first membrane having an inner edge that defines a first triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the first triangular-shaped aperture including a lower portion having a first mouth width;

a second full-face cushion, the second full-face cushion comprising a second membrane including a second nasal bridge region, second cheek regions and a second chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the second membrane having an inner edge that defines a second triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the second triangular-shaped aperture including a lower portion having a second mouth width;

a third full-face cushion, the third full-face cushion comprising a third membrane including a third nasal bridge region, third cheek regions and a third chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the third membrane having an inner edge that defines a third triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the third triangular-shaped aperture including a lower portion having a third mouth width; and

a fourth full-face cushion, the fourth full-face cushion comprising a fourth membrane including a fourth nasal bridge region, fourth cheek regions and a fourth chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the fourth membrane having an inner edge that defines a fourth triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the fourth triangular-shaped aperture including a lower portion having a fourth mouth width,

wherein, in a front view, each of the first, second, third and fourth triangular-shaped apertures has a different height, the first mouth width is within 5 mm of the second, third and fourth mouth widths, the second mouth width is within 5 mm of the third and fourth mouth widths, and the third mouth width is within 5 mm of the fourth mouth width,

wherein the first full-face cushion is a large size full-face cushion, the second full-face cushion is a medium size full-face cushion, the third full-face cushion is a small size full-face cushion and the fourth full-face cushion is a size that is smaller than the third full-face cushion, and

wherein the first full-face cushions is the largest full-face cushion in the series and the fourth full-face cushion is the smallest full-face cushion in the series, and the first mouth width is within 5 mm of the fourth mouth width, and

selecting, for the treatment, a full-face cushion from the series of full-face cushions, in accordance with a size of the patient'"'"'s face.

2. The method of claim 1, wherein each of the first, second, third and fourth full-face cushions includes a support structure, each support structure including:

a wall; and

an underlying cushion connected to the wall,

wherein each underlying cushion, in a cross-sectional view, extends from a respective wall and toward a respective breathing cavity to provide support to a respective one of the first, second, third and fourth membranes, each underlying cushion includes cheek regions extending adjacent a perimeter of a respective one of the first, second, third and fourth triangular-shaped apertures such that each respective full-face cushion has at least a double-walled construction in the cheek regions such that each underlying cushion is positioned to restrain movement of a respective one of the first, second, third and fourth membranes, and

wherein each underlying cushion is absent in a majority of the chin region of a respective one of the full-face cushions so as to allow each respective membrane to readily flex in the chin region of the respective full-face cushion.

3. The method of claim 2, wherein each wall has a top portion and a bottom portion, each of the first, second, third and fourth membranes forms a widest point of the respective full-face cushion, and the bottom portion of each wall is entirely internally offset with respect to the widest point of the respective full-face cushion, and

wherein the first, second, third and fourth triangular-shaped apertures have different mouth width to height ratios.

4. The method of claim 3, wherein a first cross-sectional configuration of the support structure in the nasal bridge region of each full-face cushion is different than a second cross-sectional configuration of the support structure in the cheek regions of the respective full-face cushion.

5. The method of claim 4, wherein the first and second cross-sectional configurations of the support structure in the nasal bridge region and the cheek regions of each respective full-face cushion vary by varying an underlying cushion offset relative to the wall.

6. The method of claim 5, wherein a first portion of each support structure extends laterally beyond a second exterior portion of a respective one of the first, second, third and fourth full-face cushions, and

wherein:

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

the first portion of each support structure is movable from an initial position towards a space exterior of the respective full-face cushion when the force is applied, and

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

7. The method of claim 6, wherein each of the first, second, third and fourth full-face cushions is adapted to exert a spring force when the force is applied such that the first portion of each support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the respective full-face cushion, and

wherein at least a portion of each support structure has a variable spring characteristic around a perimeter of the respective full-face cushion.

8. The method of claim 7, wherein the first and second cross-sectional configurations of each support structure vary from one another so as to provide a spring constant in the nasal bridge region of each respective full-face cushion that is different than a spring constant in the cheek regions of the respective full-face cushion.

9. The method of claim 8, wherein each of the first, second, third and fourth full-face cushions is dimensioned to fit respective first, second, third and fourth ranges of the patients, the mouth widths of the first, second, third and fourth triangular-shaped apertures are at a widest point of the first, second, third and fourth triangular-shaped apertures, and the height of each of the first, second, third and fourth triangular-shaped apertures is at a tallest point of the first, second, third and fourth triangular-shaped apertures.

10. The method of claim 9, wherein the first, second, third and fourth mouth widths are substantially constant.

11. The method of claim 10, wherein each of the first, second, third and fourth membranes has a height in the nasal bridge region of a respective one of the first, second, third and fourth full-face cushions that is greater than a height of the respective membrane in the cheek regions of the respective full-face cushion.

12. The method of claim 2, wherein each respective full-face cushion has only a single-walled construction formed by the respective membrane in at least a portion of the chin region.

13. The method of claim 1, wherein the first, second, third and fourth mouth widths are constant.

14. A method of selecting a cushion from a series of full-face cushions to deliver breathable gas to a patient via a mask system for treatment of Obstructive Sleep Apnea with Non-Invasive Positive Pressure Ventilation, the method comprising:

providing a series of full-face cushions, each of the full-face cushions including a nasal bridge region, cheek regions and a chin region, each of the full-face cushions defining, at least in part, a breathing cavity, the series comprising;

a first full-face cushion, the first full-face cushion comprising a first membrane including a first nasal bridge region, first cheek regions and a first chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the first membrane having an inner edge that defines a first triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the first triangular-shaped aperture including a lower portion having a first mouth width; and

a second full-face cushion, the second full-face cushion comprising a second membrane including a second nasal bridge region, second cheek regions and a second chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the second membrane having an inner edge that defines a second triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the second triangular-shaped aperture including a lower portion having a second mouth width;

wherein, in a front view, a height of the first triangular-shaped aperture is different than a height of the second triangular-shaped aperture, and the first mouth width and the second mouth width are constant,

wherein each of the full-face cushions in the series includes a support structure, each support structure including;

a wall; and

an underlying cushion connected to the wall,

wherein each underlying cushion, in a cross-sectional view, extends from a respective wall and toward a respective breathing cavity to provide support to a respective one of the membranes, each underlying cushion includes cheek regions extending adjacent a perimeter of a respective one of the triangular-shaped apertures such that each respective full-face cushion has at least a double-walled construction in the cheek regions such that each underlying cushion is positioned to restrain movement of a respective one of the membranes, and

wherein each underlying cushion is absent in a majority of the chin region of a respective one of the full-face cushions so as to allow each respective membrane to readily flex in the chin region of the respective full-face cushion, and

selecting, for the treatment, a full-face cushion from the series of full-face cushions, in accordance with a size of the patient'"'"'s face.

15. The method of claim 14, wherein the series of full-face cushions further comprises a third full-face cushion, the third full-face cushion comprising a third membrane including a third nasal bridge region, third cheek regions and a third chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the third membrane having an inner edge that defines a third triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the third triangular-shaped aperture including a lower portion having a third mouth width,

wherein, in a front view, a height of the third triangular-shaped aperture is different than the heights of the first and second triangular-shaped apertures, and the third mouth width is within 5 mm of the first and second mouth widths.

16. The method of claim 15, wherein the series of full-face cushions further comprises a fourth full-face cushion, the fourth full-face cushion comprising a fourth membrane including a fourth nasal bridge region, fourth cheek regions and a fourth chin region to seal on a nasal bridge region, cheek regions, and a chin region of the patient'"'"'s face, the fourth membrane having an inner edge that defines a fourth triangular-shaped aperture to receive the patient'"'"'s nose and mouth, the fourth triangular-shaped aperture including a lower portion having a fourth mouth width,

wherein, in a front view, a height of the fourth triangular-shaped aperture is different than the heights of the first, second and third triangular-shaped apertures, and the fourth mouth width is within 5 mm of the first, second and third mouth widths.

17. The method of claim 16, wherein each wall has a top portion and a bottom portion, each of the first, second, third and fourth membranes forms a widest point of the respective full-face cushion, and the bottom portion of each wall is entirely internally offset with respect to the widest point of the respective full-face cushion, and

wherein the first, second, third and fourth apertures have different mouth width to height ratios.

18. The method of claim 17, wherein each of the first, second, third and fourth full-face cushions is adapted to exert a spring force when the respective full-face cushion is worn and a force is applied to the respective full-face cushion, such that a first portion of each support structure is configured to resiliently move back into an initial position when the force is no longer exerted on the respective full-face cushion, and

wherein at least a portion of each support structure has a variable spring characteristic around a perimeter of the respective full-face cushion.

19. The method of claim 18, wherein a cross-sectional configuration of the support structure in a first region of each respective full-face cushion varies from a cross-sectional configuration of the support structure in a second region of the respective full-face cushion so as to provide a spring constant in the first region of the respective full-face cushion that is different than a spring constant in the second region of the respective full-face cushion.

20. The method of claim 19, wherein a first cross-sectional configuration of the support structure in the nasal bridge region of each full-face cushion is different than a second cross-sectional configuration of the support structure in the cheek regions of the respective full-face cushion.

21. The method of claim 20, wherein a third cross-sectional configuration of the support structure in a lower facial area of the cheek regions of each full-face cushion is different than a fourth cross-sectional configuration of the support structure in an upper facial area of the cheek regions of the respective full-face cushion.

22. The method of claim 21, wherein the first and second cross-sectional configurations of the support structure in the nasal bridge region and the cheek regions of each respective full-face cushion vary by varying an underlying cushion offset relative to the wall.

23. The method of claim 22, wherein each of the first, second, third and fourth full-face cushions is dimensioned to fit respective first, second, third and fourth ranges of the patients, the mouth widths of the first, second, third and fourth triangular-shaped apertures are at a widest point of the first, second, third and fourth triangular-shaped apertures, and the height of each of the first, second, third and fourth triangular-shaped apertures is at a tallest point of the first, second, third and fourth triangular-shaped apertures, and

wherein the first full-face cushion is a large size full-face cushion, the second full-face cushion is a medium size full-face cushion, the third full-face cushion is a small size full-face cushion and the fourth full-face cushion is a size that is smaller than the third full-face cushion.

24. The method of claim 23, wherein each underlying cushion includes a nasal bridge region such that each underlying cushion is continuous along the cheek regions and the nasal bridge region of each underlying cushion.

25. The method of claim 24, wherein the first, second, third and fourth mouth widths are constant.

26. The method of claim 25, wherein a first portion of each support structure extends laterally beyond a second exterior portion of a respective one of the first, second, third and fourth full-face cushions,

wherein:

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

the first portion of each support structure is movable from an initial position towards a space exterior of the respective full-face cushion when the force is applied, and

the first portion of each support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the respective full-face cushion,

wherein at least a portion of each underlying cushion forms the respective first portion of each support structure, and a respective one of the first, second, third and fourth membranes extends from each underlying cushion, and

wherein each underlying cushion includes a nasal bridge region such that each underlying cushion is continuous along the cheek regions and the nasal bridge region of the respective underlying cushion.

27. The method of claim 25, wherein a first portion of each support structure extends laterally beyond a second exterior portion of a respective one of the first, second, third and fourth full-face cushions,

wherein:

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

the first portion of each support structure is movable from an initial position towards a space exterior of the respective full-face cushion when the force is applied, and

the first portion of each support structure is configured to resiliently move back into the initial position when the force is no longer exerted on the respective full-face cushion,

wherein at least a portion of each wall forms the respective first portion of each support structure, and a respective one of the first, second, third and fourth membranes extends from each the wall, and

wherein each underlying cushion includes a nasal bridge region such that each underlying cushion is continuous along the cheek regions and the nasal bridge region of the respective underlying cushion.

28. The method of claim 16, wherein the first, second, third and fourth mouth widths are constant.

29. The method of claim 14, wherein each of the first and second full-face cushions is dimensioned to fit respective first and second ranges of the patients, and

wherein the first full-face cushion is a large size full-face cushion, and the second full-face cushion is a medium size full-face cushion.

30. The method of claim 14, wherein each respective full-face cushion has only a single-walled construction formed by the respective membrane in at least a portion of the chin region.