Cushion to frame assembly mechanism

• US 8,944,061 B2
• Filed: 03/15/2013
• Issued: 02/03/2015
• Est. Priority Date: 10/14/2005
• Status: Active Grant

• Current Assignee: Resmed Limited (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: D'Souza, Errol Savio Alex, Davidson, Aaron Samuel, Eves, Matthew, Hitchcok, Robin Garth
• Primary Examiner(s): BOUCHELLE, LAURA A
• Application Number:
  US13/834,189
• Publication Number:
  US 20130213402A1
• Time in Patent Office: 690 Days
• Field of Search: 128/206.21, 128/206.24, 128/206.28, D24/110.1, D24/110.4, D24/110.5
• US Class Current: 128/206.24
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• 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 16/0633 with forehead support
• CPC Class Codes: A61M 16/0638 in the form of a pivot
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 2205/0216 Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking

Abstract

A full-face mask assembly includes a frame, a cushion provided to the frame, the cushion adapted to form a seal around the patent'"'"'s nose and mouth and a skeleton frame to maintain the cushion to the frame, the skeleton frame including at least one of an upper support member adapted to support a forehead support, lower headgear clip receptacles adapted to be engaged with clips provided to straps of a headgear assembly, and an annular elbow connection seal adapted to engage an inlet conduit.

Claims

1. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion adapted to form a seal by abutting a patient'"'"'s face around the patient'"'"'s nose and mouth, the cushion comprising a face contacting portion with a membrane that contacts the patient'"'"'s face around the patient'"'"'s nose and mouth and a support cushion underlying at least a portion of the membrane;

a frame integrally molded to the cushion, the frame comprising an annular wall surrounding an opening that allows fluid communication of the pressurized gas to an interior of the frame and a second wall surrounding the annular wall and connected to the cushion; and

a skeleton frame removably attached to the frame, the skeleton frame comprising an upper support member adapted to receive a forehead support, a lower frame member comprising headgear attachment locations adapted to receive clips for straps of a headgear assembly, an annular hole adapted to align with the opening, and two frame members interconnecting the upper support member and the lower frame member and forming a substantially triangular open space between the two frame members and the lower frame member, wherein the frame is at least partially accessible through the substantially triangular space.

2. The mask assembly according to claim 1, wherein two headgear attachment locations of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening.

3. The mask assembly according to claim 2, wherein the two headgear attachment locations of the headgear attachment locations are disposed substantially diametrically opposite to one another with respect to the opening.

4. The mask assembly according to claim 1, wherein the frame protrudes at least partially through the triangular space.

5. The mask assembly according to claim 1, wherein the skeleton frame and the frame are adapted to engage at the opening while an inlet elbow is engaged with the mask assembly.

6. The mask assembly according to claim 1, wherein the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening.

7. The mask assembly according to claim 1, wherein the headgear attachment locations are adapted to engage with clips attached to the straps of the headgear assembly.

8. The mask assembly according to claim 1, wherein two headgear attachment locations of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening;

the frame protrudes at least partially through the triangular space;

the skeleton frame and the frame are adapted to engage at the opening while an inlet elbow is engaged with the mask assembly;

the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening; and

the two headgear attachment locations are adapted to engage with clips attached to the straps of the headgear assembly.

9. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion adapted to form a seal by abutting a patient'"'"'s face around the patient'"'"'s nose and mouth, the cushion comprising a face contacting portion with a membrane that contacts the patient'"'"'s face around the patient'"'"'s nose and mouth and a support cushion underlying at least a portion of the membrane;

a frame integrally molded to the cushion, the frame comprising an annular wall surrounding an opening that is adapted to allow fluid communication of the pressurized gas to an interior of the frame and a second wall surrounding the annular wall and connected to the cushion;

an inlet elbow to contact the frame and to communicate the pressurized gas to the interior of the frame; and

a skeleton frame adapted to be removably engageable with the frame, the skeleton frame comprising an upper support member adapted to receive a forehead support, a lower frame member comprising headgear attachment locations adapted to engage with clips for straps of a headgear assembly, two frame members interconnecting the upper support member and the lower frame member and forming an open space between the two frame members and the lower frame member, wherein

the skeleton frame and the frame are adapted to be releasably engageable to one another at the opening, and

the frame is at least partially accessible through the open space.

10. The mask assembly according to claim 9, wherein two headgear attachment locations of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening.

11. The mask assembly according to claim 10, wherein the two headgear attachment locations of the headgear attachment locations are disposed substantially diametrically opposite to one another with respect to the opening.

12. The mask assembly according to claim 9, wherein the frame protrudes at least partially through the open space.

13. The mask assembly according to claim 9, wherein the skeleton frame and the frame are adapted to engage at the opening while the inlet elbow is engaged with the mask assembly.

14. The mask assembly according to claim 9, wherein the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening.

15. The mask assembly according to claim 9, wherein the headgear attachment locations are adapted to engage with clips attached to the straps of the headgear assembly.

16. The mask assembly according to claim 9, wherein two headgear attachment locations of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening;

the frame protrudes at least partially through the open space;

the skeleton frame and the frame are adapted to engage at the opening while the inlet elbow is engaged with the mask assembly;

the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening; and

the two headgear attachment locations are adapted to engage with clips attached to the straps of the headgear assembly.

17. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a first frame made of first material;

a cushion connected to the first frame, the cushion being adapted to form a seal around a patient'"'"'s nose and mouth and being made from a second material that is more flexible than the first material; and

a second frame adapted to constrain the first frame, the second frame comprising an upper support member that supports a forehead support, two lower headgear clip attachments engaged with clips provided to straps of a headgear assembly, an annular connection adapted to engage an elbow of an inlet conduit and an opening located between the annular connection and the upper support member, the opening providing access to the first frame.

18. The mask assembly according to claim 17, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame sub-assembly.

19. The mask assembly according to claim 17, wherein the upper support member comprises an annular opening adapted to receive the forehead support.

20. The mask assembly according to claim 17, wherein the first frame is contoured to fit over the patient'"'"'s nose and mouth.

21. The mask assembly according to claim 17, wherein the first frame comprises an opening that provides a flow path adapted to communicate with the inlet conduit.

22. The mask assembly according to claim 17, wherein the second frame includes contact points to prevent rotation of the first frame with respect to the second frame.

23. The mask assembly according to claim 17, wherein the first frame and the cushion together form a breathing chamber around the patient'"'"'s nose and mouth.

24. The mask assembly according to claim 17, wherein the cushion comprises a face contacting portion with a membrane that contacts a patient'"'"'s face and a support cushion underlying at least a portion of the membrane.

25. The mask assembly according to claim 24, wherein the support cushion is omitted at a location corresponding to a patient'"'"'s chin.

26. The mask assembly according to claim 17, wherein the second frame comprises two connecting members that connect a lower portion of the second frame to the upper support member and the opening is located between the two connecting members.

27. The mask assembly according to claim 17, wherein the opening is substantially triangular.

28. The mask assembly according to claim 17, wherein the two lower headgear clip attachments are adjacent to and on opposite lateral sides of the annular connection.

29. The mask assembly according to claim 17, wherein the first frame is releasably secured to the second frame by way of an interlocking and/or frictional fit.

30. The mask assembly according to claim 17, wherein the first frame and the second frame have complementary shapes.

31. The mask assembly according to claim 17, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame assembly,

the upper support member comprises an annular opening adapted to receive the forehead support,

the cushion is contoured to fit the patient'"'"'s nose and mouth,

the first frame comprises an opening that provides a flow path adapted to communicate with the inlet conduit,

the second frame includes contact points that prevent rotation of the first frame with respect to the second frame,

the first frame and the cushion together form a breathing chamber around the patient'"'"'s nose and mouth,

the cushion comprises a face contacting portion with a membrane that contacts a patient'"'"'s face and a support cushion underlying at least a portion of the membrane,

the support cushion is omitted at a location corresponding to a patient'"'"'s chin,

the second frame comprises two connecting members that connect a lower portion of the second frame to the upper support member and the opening is located between the two connecting members,

the opening is substantially triangular,

the two lower headgear clip attachments are adjacent to and on opposite lateral sides of the annular connection,

the first frame is releasably secured to the second frame by way of an interlocking and/or frictional fit, and

the first frame and the second frame have complementary shapes.

32. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a first frame made of first material;

a cushion connected to the first frame, the cushion being adapted to form a seal around a patient'"'"'s nose and mouth and being made from a second material that is more flexible than the first material, the first frame and the cushion together forming a breathing chamber; and

a second frame adapted to constrain the first frame, the second frame comprising an upper support member adapted to assist with forehead support, two lower headgear clip attachments engaged with clips provided to straps of a headgear assembly, an annular opening adapted to allow an elbow to provide pressurized gas to the patient, and a separate opening located between the annular opening and the upper support member, the separate opening providing access to the first frame while the mask assembly is fully assembled.

33. The mask assembly according to claim 32, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame sub-assembly.

34. The mask assembly according to claim 32, wherein the upper support member comprises a second annular opening adapted to receive a forehead support.

35. The mask assembly according to claim 32, wherein the first frame is contoured to fit over the patient'"'"'s nose and mouth.

36. The mask assembly according to claim 32, wherein the first frame comprises a frame-opening that provides a flow path adapted to communicate with the elbow.

37. The mask assembly according to claim 32, wherein the second frame includes contact points contacting the first frame to prevent rotation of the first frame with respect to the second frame.

38. The mask assembly according to claim 32, wherein the first frame and the cushion together form the breathing chamber around the patient'"'"'s nose and mouth.

39. The mask assembly according to claim 32, wherein the cushion comprises a face contacting portion with a membrane that contacts a patient'"'"'s face and a support cushion underlying at least a portion of the membrane.

40. The mask assembly according to claim 39, wherein the support cushion is omitted at a location corresponding to a patient'"'"'s chin.

41. The mask assembly according to claim 32, wherein the second frame comprises two connecting members that connect a lower portion of the second frame to the upper support member, and the separate opening is located between the two connecting members.

42. The mask assembly according to claim 32, wherein the separate opening is substantially triangular.

43. The mask assembly according to claim 32, wherein the two lower headgear clip attachments are adjacent to and on opposite lateral sides of the annular opening.

44. The mask assembly according to claim 32, wherein the first frame is releasably secured to the second frame by way of an interlocking and/or frictional fit.

45. The mask assembly according to claim 32, wherein the first frame and the second frame have complementary shapes.

46. The mask assembly according to claim 32, wherein the annular opening and the elbow are sealingly connected.

47. The mask assembly according to claim 32, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame sub-assembly,

the upper support member comprises a second annular opening adapted to receive a forehead support,

the cushion is contoured to fit the patient'"'"'s nose and mouth,

the first frame comprises a frame-opening that allows for a flow path adapted to communicate with the elbow,

the second frame includes contact points that prevent rotation of the first frame with respect to the second frame,

the first frame and the cushion together form the breathing chamber around the patient'"'"'s nose and mouth,

the cushion comprises a face contacting portion with a membrane that contacts a patient'"'"'s face and a support cushion underlying at least a portion of the membrane,

the support cushion is omitted at a location corresponding to a patient'"'"'s chin,

the second frame comprises two connecting members that connect a lower portion of the second frame to the upper support member and the separate opening is located between the two connecting members,

the separate opening is substantially triangular,

the two lower headgear clip attachments are adjacent to and on opposite lateral sides of the annular opening,

the first frame is releasably secured to the second frame by way of an interlocking and/or frictional fit,

the annular opening and the elbow are sealingly connected, and

the first frame and the second frame have complementary shapes.

48. The mask assembly according to claim 32, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame sub-assembly,

the cushion is contoured to fit the patient'"'"'s nose and mouth,

the first frame comprises a frame-opening that allows for a flow path to communicate the elbow with an interior of the first frame,

the second frame includes contact points that prevent rotation of the first frame with respect to the second frame,

the first frame and the cushion together form the breathing chamber around the patient'"'"'s nose and mouth,

the cushion comprises a face contacting portion that contacts a patient'"'"'s face,

the second frame comprises two connecting members that connect a lower portion of the second frame to the upper support member and the separate opening is located between the two connecting members,

the two lower headgear clip attachments are adjacent to and on opposite lateral sides of the annular opening,

the annular opening and the elbow are sealingly connected, and

the first frame is releasably secured to the second frame by way of an interlocking and/or frictional fit.

49. The mask assembly according to claim 48, wherein the separate opening is substantially triangular and the first frame and the second frame have complementary shapes.

50. The mask assembly according to claim 48, wherein the elbow engages the second frame.

51. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a first frame with a first opening adapted to fluidly communicate an interior of the first frame with an inlet conduit, the first frame being made of a first material;

a cushion with a side wall and a face contacting portion extending from the side wall, wherein the cushion is over-molded to the first frame to form a cushion/frame sub-assembly and the cushion is adapted to form a seal around a patient'"'"'s nose and mouth, the cushion being made of a second material that is less rigid than the first material; and

a second frame adapted to removably interlock with the cushion/frame sub-assembly, the second frame including

an upper member configured to provide forehead support;

lower portion with a second opening aligned with the first opening so that the inlet conduit fluidly communicates with a breathing chamber formed by the cushion and the first frame, and with headgear attachment structures on opposed lateral sides of the second opening, the headgear attachment structures being adapted to engage with headgear attachments;

two elongate frame members that interconnect the upper member and lower portion; and

an open space bounded at least in part by the two elongate frame members and the lower portion;

wherein the first frame protrudes at least partially through the open space.

52. The mask assembly according to claim 51, wherein the first opening is surrounded by an annular wall.

53. The mask assembly according to claim 51, wherein the headgear attachments are clips provided to straps of a headgear assembly.

54. The mask assembly according to claim 51, wherein the first frame and the second frame interlock at the second opening.

55. The mask assembly according to claim 51, wherein the elongate frame members engage with the cushion/frame sub-assembly to prevent rotation of the cushion/frame sub-assembly about the second opening.

56. The mask assembly according to claim 51, wherein the inlet conduit comprises an inlet elbow.

57. The mask assembly according to claim 51, wherein the first opening is surrounded by an annular wall, the headgear attachments are clips provided to straps of a headgear assembly, the first frame and the second frame interlock at the second opening, the elongate frame members engage with the cushion/frame sub-assembly to prevent rotation of the cushion/frame sub-assembly about the second opening, and the inlet conduit comprises an inlet elbow.

58. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion adapted to form a seal by abutting a patient'"'"'s face around the patient'"'"'s nose and mouth, the cushion comprising a face contacting portion with a sealing portion that contacts the patient'"'"'s face around the patient'"'"'s nose and mouth, the cushion being made of a first material;

a frame integrally molded to the cushion, the frame comprising an annular wall surrounding a frame-opening that allows fluid communication of the pressurized gas to an interior of the frame and a second wall connected to the cushion, the frame being made of a second material more rigid than the first material; and

a skeleton frame removably attached to the frame, the skeleton frame comprising an upper support member adapted to receive a forehead contacting portion, a lower frame member comprising headgear attachment locations adapted to receive clips for straps of a headgear assembly, an annular hole adapted to align with the frame-opening, and two frame members interconnecting the upper support member and the lower frame member and forming an open space between the two frame members and the lower frame member, wherein

the frame is at least partially accessible through the open space.

59. The mask assembly according to claim 58, wherein two of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the annular hole.

60. The mask assembly according to claim 59, wherein the two headgear attachment locations are disposed substantially diametrically opposite to one another with respect to the annular hole.

61. The mask assembly according to claim 58, wherein the frame protrudes at least partially through the open space.

62. The mask assembly according to claim 58, wherein the skeleton frame and the frame are adapted to engage at the frame-opening.

63. The mask assembly according to claim 58, wherein the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the frame-opening.

64. The mask assembly according to claim 58, wherein two of the headgear attachment locations are disposed adjacent to and on substantially opposite lateral sides of the annular hole;

the frame protrudes at least partially through the open space;

the skeleton frame and the frame are adapted to engage at the frame-opening; and

the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the frame-opening.

65. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion adapted to form a seal by abutting a patient'"'"'s face around the patient'"'"'s nose and mouth, the cushion comprising a face contacting portion with a sealing portion that contacts the patient'"'"'s face around the patient'"'"'s nose and mouth and comprising a first material;

a frame integrally molded to the cushion, the frame comprising an annular wall surrounding an opening that is adapted to allow fluid communication of the pressurized gas to an interior of the frame and a second wall surrounding the annular wall and connected to the cushion and comprising a second material that is more rigid than the first material;

an inlet conduit in fluid communication with the frame to communicate the pressurized gas to the interior of the frame; and

a skeleton frame adapted to be removably engageable with the frame, the skeleton frame comprising an upper support member adapted to receive a forehead contacting portion, a lower frame member comprising attachment locations adapted to engage with clips for straps, two frame members interconnecting the upper support member and the lower frame member and forming an open space between the two frame members and the lower frame member, wherein

the skeleton frame and the frame are adapted to be releasably engageable to one another at the opening, and

the frame is at least partially accessible through the open space.

66. The mask assembly according to claim 65, wherein two of the attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening.

67. The mask assembly according to claim 66, wherein the two attachment locations are disposed substantially diametrically opposite to one another with respect to the opening.

68. The mask assembly according to claim 65, wherein the frame protrudes at least partially through the open space.

69. The mask assembly according to claim 65, wherein the skeleton frame and the frame are engaged at the opening and the inlet conduit is engaged with the mask assembly at the opening.

70. The mask assembly according to claim 65, wherein the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening.

71. The mask assembly according to claim 65, wherein the inlet conduit comprises an inlet elbow.

72. The mask assembly according to claim 65, wherein two of the attachment locations are disposed adjacent to and on substantially opposite lateral sides of the opening;

the frame protrudes at least partially through the open space;

the skeleton frame and the frame are engaged at the opening;

the inlet conduit comprises an inlet elbow that is engaged with the mask assembly at the opening; and

the skeleton frame and the frame have mutual contact points to prevent relative rotation of the frame about the opening.

73. The mask assembly according to claim 72, wherein the inlet elbow engages the skeleton frame.

74. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a first frame with a first opening surrounded by a first cylindrical wall and adapted to fluidly communicate an interior of the first frame with an inlet conduit, the first frame being made of a first material;

a cushion with a face contacting portion, wherein the cushion is over-molded to the first frame to form a cushion/frame sub-assembly and the cushion is adapted to form a seal around a patient'"'"'s nose and mouth, the cushion being made of a second material that is less rigid than the first material; and

a second frame adapted to removably interlock with the cushion/frame sub-assembly, the second frame including;

an upper member configured to support a forehead contacting portion,

a lower member with a second opening surrounded by a second cylindrical wall and aligned with the first opening so that the first cylindrical wall and the second cylindrical wall at least partially overlap when the first frame and the second frame are assembled,

two elongate frame members that interconnect the upper member and lower portion; and

an open space bounded at least in part by the two elongate frame members and the lower member;

wherein the first frame is accessible through the open space after the first frame is assembled to the second frame.

75. The mask assembly according to claim 74, wherein the second frame includes headgear attachment points on opposed lateral sides of the second opening.

76. The mask assembly according to claim 74, wherein the first frame and the second frame interlock at the second opening.

77. The mask assembly according to claim 74, wherein the elongate frame members engage with the cushion/frame sub-assembly to prevent rotation of the cushion/frame sub-assembly about the second opening.

78. The mask assembly according to claim 74, wherein the inlet conduit comprises an inlet elbow.

79. The mask assembly according to claim 74, wherein the second frame includes headgear attachment points on opposed lateral sides of the second opening, the first frame and the second frame interlock at the second opening, the elongate frame members engage with the cushion/frame sub-assembly to prevent rotation of the cushion/frame sub-assembly about the second opening, and the inlet conduit comprises an inlet elbow.

80. The mask assembly according to claim 79, wherein the inlet elbow engages the second frame.

81. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a first frame made of first material;

a cushion connected to the first frame, the cushion being adapted to form a seal around a patient'"'"'s nose and mouth and being made from a second material that is more flexible than the first material, the first frame and the cushion together forming a breathing chamber; and

a second frame adapted to constrain the first frame, the second frame comprising an upper member, a lower member with an annular opening adapted to allow an inlet conduit to provide pressurized gas to the patient, and a separate opening located between the annular opening and the upper member, the separate opening providing access to the first frame when the mask assembly is fully assembled,

wherein the first frame and the second frame snap-fit together.

82. The mask assembly according to claim 81, further comprising two elongate frame members connecting the upper member and lower member and at least partially bounding the separate opening.

83. The mask assembly according to claim 82, wherein the elongate frame members include contact points with the first frame to prevent rotation of the first frame with respect to the second frame.

84. The mask assembly according to claim 81, wherein the first frame and the cushion are integrally molded in one piece to provide a cushion-frame sub-assembly.

85. The mask assembly according to claim 81, wherein the first frame is contoured to fit over the patient'"'"'s nose and mouth.

86. The mask assembly according to claim 81, wherein the separate opening is substantially triangular.

87. The mask assembly according to claim 81, further comprising two headgear clip attachments adjacent to and on opposite lateral sides of the annular opening.

88. The mask assembly according to claim 81, wherein the inlet conduit comprises an inlet elbow.

89. The mask assembly according to claim 81, further comprising two headgear clip attachments adjacent to and on opposite lateral sides of the annular opening;

and

two elongate frame members connecting the upper member and lower member and at least partially bounding the separate opening, wherein

the elongate frame members include contact points with the first frame to prevent rotation of the first frame with respect to the second frame,

the first frame and the cushion are integrally molded in one piece to provide a cushion- frame sub-assembly,

the first frame is contoured to fit over the patient'"'"'s nose and mouth, and

the inlet conduit comprises an inlet elbow.

90. The mask assembly according to claim 89, wherein the separate opening is substantially triangular.

91. The mask assembly according to claim 89, wherein the inlet elbow engages the second frame.