Cushion for patient interface

• US 8,573,213 B2
• Filed: 11/14/2012
• Issued: 11/05/2013
• 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:
  US13/676,925
• Publication Number:
  US 20130081629A1
• Time in Patent Office: 356 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 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 aperture adapted to receive the patient'"'"'s nose and mouth; and

a support structure to support the membrane, the support structure including an underlying cushion to provide support to the membrane, the underlying cushion including a nasal bridge region, a left cheek region and a right cheek region, the underlying cushion, in cross section, including an inwardly curved portion that curves inwardly toward the breathing cavity,

wherein the membrane extends from the support structure and, from front view, covers the underlying cushion,

wherein the underlying cushion and the membrane form at least a double-walled construction in the nasal bridge region and the pair of cheek regions of the cushion, and

wherein;

the inwardly curved portion of the underlying cushion terminates at a free end of the underlying cushion,

the inwardly curved portion of the underlying cushion extends along the nasal bridge region, the left cheek region and the right cheek region of the underlying cushion, and

the inwardly curved portion of the underlying cushion terminates proximate a transition between the chin region and a respective cheek region of the cushion to form an underlying cushion cutaway profile in the chin region of the cushion, wherein the inwardly curved portion of the underlying cushion is absent in the underlying cushion cutaway profile.

2. The cushion according to claim 1, wherein the support structure includes a wall to which the underlying cushion is connected, and

wherein the membrane forms a widest point of the cushion, and a bottom portion of the wall is entirely internally offset with respect to the widest point.

3. The cushion according to claim 2, wherein 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.

4. The cushion according to claim 3, wherein the membrane extends from the underlying 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 wall.

5. The cushion according to claim 4, wherein the membrane in the nasal bridge region has a height that is greater than a height of the membrane in the pair of cheek regions of the cushion.

6. The cushion according to claim 5, wherein a third cross-sectional configuration of the support structure in a lower facial area of the pair of cheek regions is different than a fourth cross-sectional configuration of the support structure in an upper facial area of the pair of cheek regions.

7. The cushion according to claim 3, wherein the membrane extends from the wall, 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 offset of the underlying cushion relative to the wall.

8. The cushion according to claim 7, wherein the membrane in the nasal bridge region of the cushion has a height that is greater than a height of the membrane in the pair of cheek regions of the cushion.

9. The cushion according to claim 8, wherein a third cross-sectional configuration of the support structure in a lower facial area of the pair of cheek regions is different than a fourth cross-sectional configuration of the support structure in an upper facial area of the pair cheek regions.

10. The cushion according to claim 9, wherein the cushion has only a single-walled construction formed by the membrane in at least a portion of the chin region of the cushion so as to allow the membrane to flex toward the breathing cavity in the at least a portion of the chin region.

11. The cushion according to claim 10, wherein the underlying cushion is continuous along the left cheek region, the nasal bridge region and the right region of the underlying cushion.

12. The cushion according to claim 11, 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 includes at least a portion of the wall,

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.

13. The cushion according to claim 12, wherein the cushion is configured to exert a spring force when the force is exerted on the cushion such that 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.

14. The cushion according to claim 13, wherein the membrane, in the nasal bridge region of the cushion, includes sloping side portions, the sloping side portions being configured to move when the membrane is engaged with the patient'"'"'s nasal bridge region so as to conform to the patient'"'"'s nasal bridge region, and

wherein the at least double-walled construction in the nasal bridge region and the pair of cheek regions of the cushion is a double-walled construction or a triple-walled construction.

15. The cushion according to claim 14, wherein the membrane, in the nasal bridge region of the cushion, has a substantially flat portion in elevation view.

16. The cushion according to claim 15, wherein the first, third and fourth cross-sectional configurations of the support structure vary from one another so as to provide different spring constants in the nasal bridge region, the lower facial area of the pair of cheek regions and the upper facial area of the pair of cheek regions of the cushion, and

wherein the first, third and fourth cross-sectional configurations of the support structure vary by varying 1) a height, a thickness and/or a curvature of the wall and/or underlying cushion;

and/or

     2) an offset of the underlying cushion relative to the wall.

17. The cushion according to claim 3, wherein the first and second cross-sectional configurations of the support structure vary so as to provide a spring constant in the nasal bridge region of the cushion that is different than a spring constant in the pair of cheek regions of the cushion,

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, and

wherein the cushion is configured to exert a spring force when the force is exerted on the cushion such that 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.

18. The cushion according to claim 1, wherein a cross-sectional configuration of the support structure in a lower facial area of the pair of cheek regions is different than a cross-sectional configuration of the support structure in an upper facial area of the pair of cheek regions.

19. The cushion according to claim 18, wherein the cushion has only a single-walled construction formed by the membrane in at least a portion of the chin region of the cushion so as to allow the membrane to flex toward the breathing cavity in the at least a portion of the chin region.

20. The cushion according to claim 19, wherein the underlying cushion is continuous along the left cheek region, nasal bridge region and right cheek region of the underlying cushion.

21. The cushion according to claim 20, 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 includes at least a portion of the underlying 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.

22. The cushion according to claim 21, wherein the cushion is configured to exert a spring force when the force is exerted on the cushion such that 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.

23. The cushion according to claim 22, wherein the membrane, in the nasal bridge region of the cushion, includes sloping side portions, the sloping side portions being configured to move when the membrane is engaged with the patient'"'"'s nasal bridge region so as to conform to the patient'"'"'s nasal bridge region, and

wherein the at least double-walled construction in the nasal bridge region and the pair of cheek regions of the cushion is a double-walled construction or a triple-walled construction.

24. The cushion according to claim 23, wherein the membrane in the nasal bridge region of the cushion has a substantially flat portion in elevation view.

25. The cushion according to claim 23, wherein a cross-sectional configuration of the support structure in the nasal bridge region of the cushion, the cross-sectional configuration of the support structure in the lower facial area of the pair of cheek regions of the cushion and the cross-sectional configuration of the support structure in the upper facial area of the pair of cheek regions of the cushion vary from one another so as to provide different spring constants in the nasal bridge region, the lower facial area of the pair of cheek regions and the upper facial area of the pair of cheek regions of the cushion, and

wherein the cross-sectional configurations of the support structure in the nasal bridge region, the lower facial area of the pair of cheek regions and the upper facial area of the pair of cheek regions of the cushion vary by varying 1) a height, a thickness and/or a curvature of the wall and/or underlying cushion;

and/or

     2) an offset of the underlying cushion relative to the wall.

26. 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 aperture adapted to receive the patient'"'"'s nose and mouth; and

a support structure to support the membrane, the support structure including an underlying cushion to provide support to the membrane, the underlying cushion including a nasal bridge region, a left cheek region and a right cheek region,

wherein the membrane extends from the support structure and, from front view, covers the underlying cushion,

wherein the underlying cushion and the membrane form a double-walled construction in the nasal bridge region and the pair of cheek regions of the cushion such that the underlying cushion is positioned to restrain movement of the membrane, and

wherein the cushion has only a single-walled construction formed by the membrane in a majority of the chin region of the cushion so as to allow the membrane to readily flex toward the breathing cavity in the chin region of the cushion.

27. The cushion according to claim 26, wherein the support structure includes a wall to which the underlying cushion is connected, the membrane forms a widest point of the cushion, and a bottom portion of the wall is entirely internally offset with respect to the widest point,

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 a first cross-sectional configuration of the support structure in the nasal bridge region of the cushion varies from a second cross-sectional configuration of the support structure in the pair of cheek regions of the cushion by varying an underlying cushion offset relative to the wall,

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, and

wherein the underlying cushion is absent in a majority of the chin region of the cushion.

28. 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 aperture adapted to receive the patient'"'"'s nose and mouth; and

a support structure to support the membrane, the support structure including an underlying cushion to provide support to the membrane, the underlying cushion including a nasal bridge region, a left cheek region and a right cheek region,

wherein the membrane extends from the support structure and covers at least part of the underlying cushion, and

wherein the underlying cushion is absent a majority of the chin region of the cushion such that a portion of the membrane is unrestrained by the underlying cushion in at least a portion of the chin region of the cushion, so as to allow the membrane to flex in the at least a portion of the chin region.

29. The cushion according to claim 28, wherein the support structure includes a wall to which the underlying cushion is connected, the membrane forms a widest point of the cushion, and a bottom portion of the wall is entirely internally offset with respect to the widest point,

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 a first cross-sectional configuration of the support structure in the nasal bridge region of the cushion varies from a second cross-sectional configuration of the support structure in the pair of cheek regions of the cushion by varying an underlying cushion offset relative to the wall,

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.

30. The cushion according to claim 29, wherein the cushion has only a single-walled construction formed by the membrane in at least a portion of the chin region of the cushion.