Mask system with snap-fit shroud

• US 9,770,568 B2
• Filed: 02/23/2017
• Issued: 09/26/2017
• Est. Priority Date: 03/04/2008
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Ng, Eva, Lockwood, David James, Wehbeh, Jamie Graeme, Valcic, Zoran, D'Souza, Errol Savio Alex, Eves, Matthew, Sari, Mahsita Darwani
• Primary Examiner(s): Ditmer, Kathryn E
• Application Number:
  US15/440,972
• Publication Number:
  US 20170157352A1
• Time in Patent Office: 215 Days
• CPC Class Codes: A61M 16/0057 Pumps therefor
• CPC Class Codes: A61M 16/0066 Blowers or centrifugal pumps
• 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: A61M 16/0633 with forehead support
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0694 Chin straps
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 16/0825 with ball-sockets
• CPC Class Codes: A61M 16/0841 for sampling
• CPC Class Codes: A61M 16/0858 Pressure sampling ports
• CPC Class Codes: A61M 16/0875 Connecting tubes
• CPC Class Codes: A61M 16/20 Valves specially adapted to medical respiratory devices
• CPC Class Codes: A61M 16/208 Non-controlled one-way valves, e.g. exhalation, check, pop-off non-rebreathing valves
• CPC Class Codes: A61M 2016/0661 with customised shape
• CPC Class Codes: A61M 2202/0085 product washed out
• CPC Class Codes: A61M 2202/0225 Carbon oxides, e.g. Carbon dioxide

Abstract

A shroud (1020) for a mask system includes a retaining portion structured to retain a frame (1040), a pair of upper headgear connectors (1024) each including an elongated arm (1026) and a slot (1027) at the free end of the arm adapted to receive a headgear strap, and a pair of lower headgear connectors (1025) each adapted to attach to a headgear strap. The retaining portion, the upper headgear connectors, and the lower headgear connectors are integrally formed as a one piece structure.

Claims

1. A mask system to provide positive air pressure therapy to a patient, the mask system comprising:

a cushion module comprising;

a frame having an interior surface forming a breathing chamber, the frame including a circular frame opening positioned to receive a supply of air at positive pressure, wherein the frame includes a cylindrical collar surrounding the frame opening and extending away from an exterior surface of the frame, the collar having a longitudinal axis, and the collar having a cylindrical surface with an axis that is coincident with the longitudinal axis of the collar, wherein the collar includes at least one radial protrusion extending from the cylindrical surface, the at least one radial protrusion having a curvature centered about the longitudinal axis of the collar, wherein the frame, including the collar and the at least one radial protrusion, is constructed from polycarbonate, and

a cushion constructed of silicone, the polycarbonate of the frame being harder than the silicone of the cushion, the frame being more rigid than the cushion, the cushion configured to seal against the patient'"'"'s face in use to enable the supply of air at positive pressure to be delivered to the patient, the cushion is constructed to engage the patient'"'"'s face along a nasal bridge region, a cheek region, and a lower lip/chin region of the patient'"'"'s face when in use,

wherein the cushion and the frame are joined to form a one-piece, integrated component;

an elbow configured to receive the supply of air at positive pressure and deliver the supply of air at positive pressure to the breathing chamber, the elbow having an anti-asphyxia valve;

a shroud without a forehead support, the shroud configured to removably connect to the frame of the cushion module, wherein the shroud includes a circular elbow opening that accommodates the elbow, wherein the shroud includes a rear surface at least partly covering the exterior surface of the frame, the shroud having a plurality of part-annular snap connection portions circumferentially spaced from one another and centered about a longitudinal axis of the elbow opening, the snap connection portions being positioned rearward of the elbow opening of the shroud, wherein the shroud, including the snap connection portions, is constructed from polycarbonate, the polycarbonate of the shroud being harder than the silicone of the cushion, and the shroud being more rigid than the cushion;

headgear configured to connect to the shroud to maintain the cushion module in position on the patient'"'"'s head in use, the headgear comprising a pair of upper straps, each of the pair of upper straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use, and a pair of lower straps, each of the pair of lower straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use; and

a vent arrangement having a plurality of holes for gas washout from the breathing chamber to atmosphere,

wherein;

the shroud includes a pair of upper headgear connectors and a pair of lower headgear connectors, said pair of upper headgear connectors structured to connect to said headgear, and said pair of lower headgear connectors structured to connect to said headgear via clips,

each of the pair of upper headgear connectors comprises an elongated arm to direct a corresponding one of the pair of upper straps away from the patient'"'"'s corresponding eye, each elongated arm being shaped to follow contours of the patient'"'"'s face and avoid the patient'"'"'s line of sight in use,

a portion of each elongated arm is enveloped by a fabric sleeve,

each elongated arm is constructed of a flexible material,

each elongated arm is connected to the shroud,

each elongated arm is configured to be positioned inferior to the patient'"'"'s corresponding eye in use and is configured to direct a corresponding one of the pair of upper straps superior to the patient'"'"'s corresponding ear in use,

each of the pair of lower headgear connectors is configured to direct a corresponding one of the pair of lower straps inferior to the patient'"'"'s corresponding ear in use

to releasably connect the shroud to the cushion module, the at least one radial protrusion and the snap connection portions are structured to resiliently deflect relative to one another in a radial direction relative to the longitudinal axis of the collar to form a removable snap-fit connection between the at least one radial protrusion and the snap connection portions by moving the cushion module and the shroud towards one another along the longitudinal axis of the collar,

when the collar and the snap connection portions are joined to form the removable snap-fit connection, the cushion module and the shroud are stabilized against rotation relative to one another,

the elbow is directly attached to the shroud at the elbow opening, and

the elbow is rotatable 360°

relative to the shroud.

2. The mask system of claim 1, wherein the frame includes a rearwardly extending portion that is constructed of the polycarbonate of the frame, the rearwardly extending portion extending rearward from the collar and terminating in an edge having a substantially triangular shape, and

wherein the cushion is joined to the frame about the edge.

3. The mask system of claim 2, wherein the rearwardly extending portion includes the interior surface of the frame that forms the breathing chamber.

4. The mask system of claim 1,

wherein the collar, the shroud, and the elbow are structured such that a plane perpendicular to the longitudinal axis of the collar intersects each of the shroud, the elbow, and the collar when the frame, the shroud, and the elbow are assembled.

5. The mask system of claim 1, wherein a portion of the shroud surrounding the elbow opening, a portion of the elbow that engages the shroud at the elbow opening, and the collar of the frame are arranged such that a plane perpendicular to the longitudinal axis of the collar intersects each of the shroud, the elbow, and the collar when the frame, the shroud, and the elbow are assembled together.

6. The mask system of claim 1, wherein the collar comprises a front end positioned to face away from the patient in use, and

wherein when the frame and the shroud are assembled together, the front end of the collar is positioned rearward of the rear surface of the shroud.

7. The mask system of claim 1, wherein:

the frame includes a rearwardly extending portion that is constructed of the polycarbonate of the frame, the rearwardly extending portion extending rearward from the collar and terminating in an edge having a substantially triangular shape,

the cushion is joined to the frame about the edge,

the rearwardly extending portion includes the interior surface of the frame that forms the breathing chamber,

the collar, the shroud, and the elbow are structured such that a plane perpendicular to the longitudinal axis of the collar intersects each of the shroud, the elbow, and the collar when the frame, the shroud, and the elbow are assembled,

the collar comprises a front end positioned to face away from the patient in use,

the collar and the snap-fit connection are arranged to remain stationary relative to one another as the elbow is rotated, and

when the frame and the shroud are assembled together, the front end of the collar is positioned rearward of the rear surface of the shroud.

8. The mask system of claim 7, wherein the at least one radial protrusion further comprises a single radial protrusion having an annular shape.

9. The mask system of claim 1, wherein the collar and the snap-fit connection are arranged to remain stationary relative to one another as the elbow is rotated.

10. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 1;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

11. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 7;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

12. A mask system to provide positive air pressure therapy to a patient, the mask system comprising:

a cushion module comprising;

a frame having an interior surface forming a breathing chamber, the frame including a circular frame opening positioned to receive a supply of air at positive pressure, wherein the frame includes a cylindrical collar surrounding the frame opening and extending away from an exterior surface of the frame, the collar having a longitudinal axis, and the collar having a cylindrical surface with an axis that is coincident with the longitudinal axis of the collar, wherein the collar includes a first radial protrusion and a second radial protrusion extending from the cylindrical surface, each of the first radial protrusion and the second radial protrusion having a part-annular shape and having a curvature centered about the longitudinal axis of the collar, wherein the frame, including the collar and each of the first radial protrusion and the second radial protrusion, is constructed from a first material, and

a cushion constructed of an elastomeric material that is a different material from the first material, the first material of the frame being harder than the elastomeric material of the cushion, the frame being more rigid than the cushion, the cushion configured to seal against the patient'"'"'s face in use to enable the supply of air at positive pressure to be delivered to at least the patient'"'"'s nose,

wherein the cushion and the frame are joined to form a one-piece, integrated component;

an elbow configured to receive the supply of air at positive pressure and deliver the supply of air at positive pressure to the breathing chamber;

a shroud configured to removably connect to the frame of the cushion module, wherein the shroud includes a circular elbow opening that accommodates the elbow, wherein the shroud includes a rear surface at least partly covering the exterior surface of the frame, the shroud having a first part-annular snap finger and a second part-annular snap finger circumferentially spaced from one another and centered about a longitudinal axis of the elbow opening, the first part-annular snap finger and the second part-annular snap finger being positioned rearward of the elbow opening of the shroud, wherein the shroud, including the first part-annular snap finger and the second part-annular snap finger, is constructed from a second material, the second material of the shroud being harder than the elastomeric material of the cushion, and the shroud being more rigid than the cushion;

headgear configured to connect to the shroud to maintain the cushion module in position on the patient'"'"'s head in use; and

a vent arrangement having a plurality of holes for gas washout from the breathing chamber to atmosphere,

wherein the shroud includes a pair of upper headgear connectors and a pair of lower headgear connectors, said pair of upper headgear connectors structured to connect to said headgear, and said pair of lower headgear connectors structured to connect to said headgear via clips,

wherein, to releasably connect the shroud to the cushion module, each of the first radial protrusion and the second radial protrusion and a corresponding one of the first part-annular snap finger and the second part-annular snap finger are structured to resiliently deflect relative to one another in a radial direction relative to the longitudinal axis of the collar to form a removable snap-fit connection between the first radial protrusion and the second radial protrusion and the first part-annular snap finger and the second part-annular snap finger by moving the cushion module and the shroud towards one another along the longitudinal axis of the collar, and

wherein when the first radial protrusion and the second radial protrusion and the first part-annular snap finger and the second part-annular snap finger are joined to form the removable snap-fit connection, the cushion module and the shroud are stabilized against rotation relative to one another.

13. The mask system of claim 12, wherein:

the cylindrical surface is on an exterior of the collar,

the first radial protrusion and the second radial protrusion are spaced circumferentially about the cylindrical surface,

the first radial protrusion and the second radial protrusion and the first part-annular snap finger and the second part-annular snap finger are configured to form the removable snap-fit connection between a front end of the cylindrical surface and a rear end of the cylindrical surface,

the cushion is constructed to engage the patient'"'"'s face along a nasal bridge region, a cheek region, and an upper lip region of the patient'"'"'s face when in use,

the elastomeric material of the cushion is silicone,

the shroud does not include a forehead support,

the first material is polycarbonate,

the second material is polycarbonate,

the cushion and the frame are joined by a chemical bond,

the elbow is directly attached to the shroud at the elbow opening,

the elbow is rotatable 360°

relative to the shroud,

the first part-annular snap finger and the second part-annular snap finger are arranged to remain stationary relative to the first radial protrusion and the second radial protrusion as the elbow is rotated,

the headgear comprises a pair of upper straps, each of the pair of upper straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use, and a pair of lower straps, each of the pair of lower straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use,

each of the pair of upper headgear connectors comprises an elongated arm to direct a corresponding one of the pair of upper straps away from the patient'"'"'s corresponding eye, each elongated arm being shaped to follow contours of the patient'"'"'s face and avoid the patient'"'"'s line of sight in use,

each elongated arm has an inner surface including a cheek pad,

each elongated arm is constructed of a flexible material,

each elongated arm is configured to be positioned inferior to the patient'"'"'s corresponding eye in use and is configured to direct a corresponding one of the pair of upper straps superior to the patient'"'"'s corresponding ear in use,

each of the pair of lower headgear connectors is configured to direct a corresponding one of the pair of lower straps inferior to the patient'"'"'s corresponding ear in use, and

the mask system further includes a seal at an interface between the elbow and the frame.

14. The mask system of claim 12, wherein:

the cushion is constructed to engage the patient'"'"'s face along a nasal bridge region, a cheek region, and a lower lip/chin region of the patient'"'"'s face when in use,

the elastomeric material of the cushion is silicone,

the cushion and the frame are constructed and arranged to be in an interlocking relationship with one another,

the first material is polycarbonate,

the second material is polycarbonate,

said headgear comprises hook and loop material,

the shroud further comprises a forehead support,

the elbow is directly attached to the shroud at the elbow opening,

the elbow includes an anti-asphyxia valve,

the collar and the snap-fit connection are arranged to remain stationary relative to one another as the elbow is rotated,

the vent arrangement comprises a protruding vent arrangement that protrudes from the frame, the protruding vent arrangement including a vent-wall having the plurality of holes, the vent-wall being spaced from the frame by a lower wall and two lateral side walls of the protruding vent arrangement, and the protruding vent arrangement positioned above the frame opening,

the first radial protrusion and the second radial protrusion are spaced circumferentially about the frame opening,

the first radial protrusion and the second radial protrusion and the first part-annular snap finger and the second part-annular snap finger are configured to form the removable snap-fit connection between a front end of the cylindrical surface and a rear end of the cylindrical surface relative to the patient in use,

the headgear comprises a pair of upper straps, each of the pair of upper straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use, and a pair of lower straps, each of the pair of lower straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use,

each of the pair of upper headgear connectors is configured to direct a corresponding one of the pair of upper straps superior to the patient'"'"'s corresponding ear in use,

each of the pair of lower headgear connectors is configured to direct a corresponding one of the pair of lower straps inferior to the patient'"'"'s corresponding ear in use,

the part-annular shape of each of the first part-annular snap finger and the second part-annular snap finger has a curvature that is centered on the longitudinal axis of the collar,

a region of the cushion positioned to engage the nasal bridge region of the patient is configured to allow increased movement compared to another region of the cushion that is adapted to seal with another region of the patient'"'"'s face, and

the mask system being constructed so that the snap-fit connection is established when a force is applied to move the shroud and cushion module toward one another along the longitudinal axis until a ramped rear end of each of the first part-annular snap finger and the second part-annular snap finger initially contacts a front end of a corresponding one of the first radial protrusion and the second radial protrusion on the collar, whereupon further application of the force causes each of the first part-annular snap finger and the second part-annular snap finger to ride over a corresponding one of the first radial protrusion and the second radial protrusion and therefore resiliently deflect in a first radial direction, and upon further movement towards one another, each of the first part-annular snap finger and the second part-annular snap finger resiliently moves in a second radial direction, opposite the first radial direction, and engages a rear end of a corresponding one of the first radial protrusion and the second radial protrusion to snap each of the first part-annular snap finger and the second part-annular snap finger into place, thereby removably connecting the shroud and the cushion module.

15. The mask system of claim 12, wherein:

the first radial protrusion and the second radial protrusion are spaced circumferentially about the cylindrical surface,

the cushion is constructed to engage the patient'"'"'s face along a nasal bridge region, a cheek region, and an upper lip region of the patient'"'"'s face when in use,

the cushion and the frame are constructed and arranged to be in an interlocking relationship with one another,

the elastomeric material of the cushion is silicone,

said headgear comprises hook and loop material,

the shroud includes a forehead support,

the first material is polycarbonate,

the second material is polycarbonate,

the elbow is directly attached to the shroud at the elbow opening,

the elbow is rotatable 360°

relative to the shroud,

the collar and the snap-fit connection are arranged to remain stationary relative to one another as the elbow is rotated,

the headgear comprises a pair of upper straps, each of the pair of upper straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use, and a pair of lower straps, each of the pair of lower straps configured to be positioned on a corresponding lateral side of the patient'"'"'s head in use,

each of the pair of upper headgear connectors is configured to direct a corresponding one of the pair of upper straps superior to the patient'"'"'s corresponding ear in use,

each of the pair of lower headgear connectors is configured to direct a corresponding one of the pair of lower straps inferior to the patient'"'"'s corresponding ear in use,

the part-annular shape of each of the first part-annular snap finger and the second part-annular snap finger has a curvature that is centered on the longitudinal axis of the collar,

a region of the cushion positioned to engage the nasal bridge region of the patient is configured to allow increased movement compared to another region of the cushion that is adapted to seal with another region of the patient'"'"'s face, and

the mask system being constructed so that the snap-fit connection is established when a force is applied to move the shroud and cushion module toward one another along the longitudinal axis until a ramped rear end of each of the first part-annular snap finger and the second part-annular snap finger initially contacts a front end of a corresponding one of the first radial protrusion and the second radial protrusion on the collar, whereupon further application of the force causes each of the first part-annular snap finger and the second part-annular snap finger to ride over a corresponding one of the first radial protrusion and the second radial protrusion and therefore resiliently deflect in a first radial direction, and upon further movement towards one another, each of the first part-annular snap finger and the second part-annular snap finger resiliently moves in a second radial direction, opposite the first radial direction, and engages a rear end of a corresponding one of the first radial protrusion and the second radial protrusion to snap each of the first part-annular snap finger and the second part-annular snap finger into place, thereby removably connecting the shroud and the cushion module.

16. The mask system of claim 15, further comprising at least one tab and recess arrangement positioned circumferentially between mating ones of the first part-annular snap finger and the second part-annular snap finger and the first radial protrusion and the second radial protrusion, the tab and recess arrangement resisting rotation of the collar relative to the shroud upon establishing the snap-fit connection between the shroud and the cushion module.

17. The mask system of claim 12, wherein the collar and the snap-fit connection are arranged to remain stationary relative to one another as the elbow is rotated.

18. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 12;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

19. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 13;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

20. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 14;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

21. A system for treating a patient with sleep disordered breathing, comprising:

the mask system of claim 15;

a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and

an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.