Cushion for patient interface

• US 8,573,215 B2
• Filed: 11/29/2012
• 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:
  US13/688,875
• Publication Number:
  US 20130086795A1
• Time in Patent Office: 341 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 making a series of full-face cushions for patient interfaces that deliver breathable gas to patients, 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 method comprising:

making 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 forming a first continuous sealing structure to form a continuous 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;

making 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 forming a second continuous sealing structure to form a continuous 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;

making 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 forming a third continuous sealing structure to form a continuous 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

making 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 forming a fourth continuous sealing structure to form a continuous 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, and the first, second, third, and fourth mouth widths are the same.

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 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 so as to allow each respective membrane to readily flex in said at least a portion of the chin region.

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 the making of the first, second, third and fourth full-face cushions comprises molding at least a portion of the first, second, third and fourth full-face cushions.

5. The method of claim 4, 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.

6. The method of claim 5, 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.

7. The method of claim 6, 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 respective well.

8. The method of claim 7, 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.

9. The method of claim 8, 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.

10. The method of claim 9, 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.

11. The method of claim 10, wherein the first, third and fourth cross-sectional configurations of each support structure vary from one another so as to provide different spring constants in the nasal bridge region, the lower facial area of the cheek regions and the upper facial area of the cheek regions of each respective full-face cushion.

12. The method of claim 11, wherein each of the first, second, third and fourth membranes, in a respective nasal bridge region, includes a contoured portion that curves inwardly and terminates at the inner edge of the respective membrane, each contoured portion being configured to follow a contour or curvature of the patient'"'"'s nasal bridge region.

13. The method of claim 11, 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,

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, and

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.

14. The method of claim 11, 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 wall,

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, and

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.

15. The method of claim 2, wherein the cheek regions of each underlying cushion terminate proximate a transition between the chin region and a respective cheek region of a respective one of the full-face cushions to form an underlying cushion cutaway profile in the chin region of the respective full-face cushion, and

wherein each underlying cushion is absent in the underlying cushion cutaway profile of the respective full-face cushion.

16. A method of making a series of full-face cushions for patient interfaces that deliver breathable gas to patients, 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 method comprising:

making 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 forming a first continuous sealing structure to form a continuous 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

making 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 forming a second continuous sealing structure to form a continuous 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 is substantially the same as the second mouth width,

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 formed by the underlying cushion and the respective membrane in the cheek regions such that each underlying cushion is positioned to restrain movement of the respective membrane, and each respective full-face cushion has only a single-walled construction formed by the respective membrane in a majority of the chin region so as to allow each respective membrane to readily flex in the chin region of the cushion.

17. The method of claim 16, further comprising:

making 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 forming a third continuous sealing structure to form a continuous 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 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.

18. The method of claim 17, further comprising:

making 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 forming a fourth continuous sealing structure to form a continuous 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 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.

19. The method of claim 18, 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.

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 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.

22. The method of claim 21, 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.

23. The method of claim 22, 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 respective wall.

24. The method of claim 23, 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.

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

26. The method of claim 25, wherein each of the first, second, third and fourth membranes, in the nasal bridge region, has a substantially flat portion in elevation view.

27. The method of claim 24, 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.

28. The method of claim 27, 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.

29. The method of claim 27, 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 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.

30. The method of claim 16, wherein the cheek regions of each underlying cushion terminate proximate a transition between the chin region and a respective cheek region of a respective one of the full-face cushions to form an underlying cushion cutaway profile in the chin region of the respective full-face cushion, and

wherein each underlying cushion is absent in the underlying cushion cutaway profile of the respective full-face cushion.