Mask system

• US 9,895,503 B2
• Filed: 08/02/2013
• Issued: 02/20/2018
• Est. Priority Date: 05/02/2003
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Jones, Michael Andrew, Amarasinghe, Amal Shirley, Fu, Timothy Tsun-Fai, Lithgow, Perry David, Saada, Jim, Sweeney, Fiachra Marcus
• Primary Examiner(s): Douglas, Steven
• Application Number:
  US13/957,475
• Publication Number:
  US 20130312758A1
• Time in Patent Office: 1,663 Days
• Field of Search: 12820421, 12820525, 12820621, 12820624, 12820628, 12820713
• CPC Class Codes: A61M 16/0057 Pumps therefor
• 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 16/0633 with forehead support
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 16/0825 with ball-sockets
• CPC Class Codes: A61M 16/0858 Pressure sampling ports
• CPC Class Codes: A61M 2210/0618 Nose
• CPC Class Codes: A62B 18/02 Masks gas-masks for animals A62B18/06; masks for welders A61F9/06

Abstract

A mask system for treating sleep disordered breathing, comprising headgear, a shell/cushion including a channel adjacent a front aperture, a frame, an elbow including at least one undercut on a proximal end, a retaining ring including a rear flange adapted to be retainably insertable in the channel of the shell/cushion, and a front flange adapted to retainably engage with the at least one undercut of the elbow.

Claims

1. A mask system for treating sleep disordered breathing, comprising:

a flexible shell and cushion unit including a cushion portion and a shell portion, the cushion portion having a face contacting portion adapted to form a seal with a patient'"'"'s face when engaged with the patient'"'"'s face, the face contacting portion including a nasal bridge region, a lip region and side regions extending between the nasal bridge region and the lip region, the shell portion including a front face with a centrally located aperture opposite the cushion portion, a channel formed in the shell portion adjacent the centrally located aperture, the flexible shell and cushion unit being an integral single piece of silicone defining an interior breathing chamber, the flexible shell and cushion unit including a rear flange, a plurality of front flanges and a plurality of discrete frame-receiving channels between the rear flange and the plurality of front flanges;

a rigid, generally triangularly-shaped frame with rounded lower corners, at least a part of the frame being shaped to be secured between the rear flange and the plurality of front flanges, the frame supporting the shell and cushion unit, the frame having at least one opening through which at least part of the shell portion extends with the frame secured to and positively located relative to the flexible shell and cushion unit;

a rigid ring-shaped member including an annular front flange ring and a rear flange ring with an annular groove between the front and rear flange rings, the rear flange ring received within the channel formed in the shell portion adjacent the aperture with part of the shell portion secured inside the annular groove, the front flange ring resting on an exterior surface of the front face of the shell portion;

a rotatable elbow having a first end and a second end, the first end being adapted to engage with and rotate relative to the ring-shaped member, the rotatable elbow having a vent including at least one vent orifice adapted to vent exhaled gases out of the rotatable elbow;

a swivel provided to the second end of the rotatable elbow, the swivel including a first end engaged with the rotatable elbow, and the swivel having a second end adapted to engage an air delivery conduit;

a port including a port cap adapted to cover and seal the port;

headgear attachment points formed on the frame, a first pair of the headgear attachment points being provided on a first side portion of the frame, and a second pair of the headgear attachment points being provided on a second side portion of the frame; and

headgear adapted to attach to the headgear attachment points.

2. The mask system of claim 1, wherein the ring-shaped member is separate from the frame.

3. The mask system of claim 2, wherein the plurality of front flanges are spaced around the centrally located aperture.

4. The mask system of claim 3, wherein the plurality of front flanges include at least four flanges.

5. The mask system of claim 3, wherein the rear flange of the shell and cushion unit is substantially continuous along the lip region and side regions.

6. The mask system of claim 3, wherein the headgear includes four straps including a pair of lower straps and a pair of upper straps, the lower straps being adapted to be positioned below a patient'"'"'s ears, the upper straps being adapted to be positioned above the patient'"'"'s ears.

7. The mask system of claim 6, wherein the frame and the shell portion are structured to be removably attachable to and detachable from each other.

8. The mask system of claim 7, wherein the ring-shaped member and the shell portion are structured to be removably attachable to and detachable from each other.

9. The mask system of claim 8, wherein the channel formed in the shell portion adjacent the centrally located aperture has a complementary shape to the rear flange ring of the ring-shaped member.

10. The mask system of claim 9, wherein the rotatable elbow includes an approximately 90°

bend between the first and second ends thereof.

11. The mask system of claim 1, wherein the frame has a width of approximately 90 mm.

12. The mask system of claim 1, wherein the headgear attachment points include four headgear attachment points.

13. The mask system of claim 1, wherein the headgear attachment points include a mushroom headed spigot adapted to connect to the headgear.

14. The mask system of claim 1, wherein the headgear attachment points include an aperture adapted to receive the headgear.

15. The mask system of claim 1, wherein the port cap comprises either a polypropelene or silicone material.

16. The mask system of claim 1, wherein the rotatable elbow comprises either a polycarbonate or polypropylene material.

17. The mask system of claim 1, wherein the ring-shaped member and the frame comprise a common material.

18. The mask system of claim 1, wherein an exterior surface of the shell and cushion unit includes a finish to increase comfort.

19. The mask system of claim 1, wherein the frame and the ring-shaped member have a common rigidity.

20. A mask system for treating sleep disordered breathing, comprising:

a flexible shell and cushion unit including a cushion portion configured to form a seal with a patient when engaged with the patient'"'"'s face, and including a shell portion, the shell portion including a front face with a centrally located aperture, the flexible shell and cushion unit being an integral single piece of silicone defining an interior breathing chamber, the flexible shell and cushion unit including a rear flange, a plurality of front flanges and a plurality of discrete frame-receiving channels between the rear flange and the plurality of front flanges;

a rigid frame including at least one portion shaped to fit into and be secured within the plurality of discrete frame-receiving channels, the frame supporting the shell and cushion unit;

a rigid ring-shaped member with an annular front flange ring and a rear flange ring with an annular groove between the front and rear flange rings, the annular front flange ring and the rear flange ring adapted to engage with the centrally located aperture of the shell portion;

a rotatable elbow having a first end and a second end, the first end adapted to engage with the ring-shaped member; and

headgear adapted to attach to the frame.

21. The mask system of claim 20, wherein the ring-shaped member is separate from the frame.

22. The mask system of claim 21, wherein the plurality of front flanges are spaced around the centrally located aperture.

23. The mask system of claim 22, wherein the plurality of front flanges include at least four spaced front flanges.

24. The mask system of claim 22, wherein the headgear includes four straps including a pair of lower straps and a pair of upper straps, the lower straps being adapted to be positioned below a patient'"'"'s ears, the upper straps being adapted to be positioned above the patient'"'"'s ears.

25. The mask system of claim 24, wherein the frame and the shell portion are removably attachable to and detachable from each other.

26. The mask system of claim 25, wherein the ring-shaped member and the shell portion are structured to be removably attachable to and detachable from each other.

27. The mask system of claim 26, wherein the rotatable elbow includes an approximately 90°

bend between the first and second ends thereof.

28. The mask system of claim 20, wherein the ring-shaped member and the frame comprises a common material.

29. The mask system of claim 20, wherein the rotatable elbow comprises either a polycarbonate or polypropylene material.

30. The mask system of claim 20, wherein an exterior surface of the shell and cushion unit includes a finish to increase comfort.

31. The mask system of claim 20, wherein the frame and the ring-shaped member have a common rigidity.

32. The mask system of claim 20, further comprising headgear attachment points formed on the frame, the headgear attachment points including a mushroom headed spigot adapted to connect to the headgear.

33. The mask system of claim 20, further comprising headgear attachment points formed on the frame, the headgear attachment points including an aperture adapted to receive the headgear.

34. The mask system of claim 20, wherein the frame has a width of approximately 90 mm.

35. A mask system for treating sleep disordered breathing, comprising:

a flexible shell and cushion unit including a cushion portion configured to form a seal with a patient when engaged with the patient'"'"'s face, and including a shell portion, the shell portion including a front face with a centrally located aperture, the flexible shell and cushion unit being an integral single piece of silicone defining a breathing chamber, the flexible shell and cushion unit including a rear flange and a plurality of front flanges, the plurality of front flanges being positioned on opposite sides of a front of the shell portion;

a rigid frame secured to and positively located relative to the flexible shell and cushion unit such that the frame remains in position between the rear flange and each of the plurality of front flanges;

a rigid ring-shaped member including a rear end positioned at least partially within the centrally located aperture of the shell portion to communicate with the interior of the breathing chamber;

a rotatable elbow having a first end and a second end, the first end adapted to engage with the ring-shaped member;

headgear attachment points formed on the frame, the headgear attachment points being provided on a first side portion and a second side portion of the frame; and

headgear adapted to attach to the headgear attachment points.

36. The mask system of claim 35, further comprising a swivel provided to the second end of the rotatable elbow, the swivel including a first end engaged with the rotatable elbow, and the swivel having a second end adapted to engage an air delivery conduit.

37. The mask system of claim 35, wherein the ring-shaped member and the frame comprise a common material.

38. The mask system of claim 35, wherein the headgear attachment points include a slot adapted to receive and retain the headgear.

39. The mask system of claim 35, wherein the rotatable elbow comprises either a polycarbonate or polypropylene material.

40. The mask system of claim 35, wherein an exterior surface of the shell and cushion unit includes a finish to increase comfort.

41. The mask system of claim 35, wherein the frame and the ring-shaped member have a common rigidity.

42. The mask system of claim 35, wherein the rotatable elbow includes an approximately 90°

bend between the first and second ends thereof.

43. The mask system of claim 35, wherein the frame and the shell portion are structured to be removably attachable to and detachable from each other.

44. The mask system of claim 35, wherein the ring-shaped member and the shell portion are structured to be removably attachable to and detachable from each other.

45. The mask system of claim 35, wherein the cushion portion includes a face contacting portion adapted to form the seal with the patient'"'"'s face when engaged with the patient'"'"'s face, the face contacting portion including a nasal bridge region, a lip region and side regions extending between the nasal bridge region and the lip region.

46. The mask system of claim 35, wherein the frame has a width of approximately 90 mm.

47. A mask system for treating sleep disordered breathing, comprising:

headgear;

a flexible shell and cushion unit including a cushion portion configured to form a seal with a patient when engaged with the patient'"'"'s face, and including a shell portion having a centrally located aperture, the shell portion having at least one flange, the flexible shell and cushion unit being an integral single piece of silicone defining a breathing chamber;

a rigid frame supporting the shell and cushion unit, the frame being generally structured and configured so that when the frame is secured to the flexible shell and cushion unit, the frame remains in position adjacent to the at least one flange of the shell portion;

a rigid ring-shaped member including a rear end positioned at least partially within the centrally located aperture of the shell portion to communicate with the interior of the breathing chamber; and

an elbow engaging with the ring-shaped member.

48. The mask system according to claim 47, further comprising at least one frame-receiving channel defined by a front surface and a rear surface, and the rigid frame includes at least one portion shaped to fit into and be secured within the at least one frame-receiving channel, with at least one edge of the frame engaging the front and rear surfaces defining the at least one frame-receiving channel.

49. The mask system according to claim 48, wherein the at least one flange comprises a substantially continuous peripheral flange at least along a lip region and side regions of the cushion portion.

50. The mask system according to claim 47, wherein the ring-shaped member includes an annular front flange, the rear end of the ring-shaped member having an outer circumferential surface that engages with an inner circumferential surface defined by a wall of the centrally located aperture.

51. The mask system according to claim 50, wherein the elbow is a rotatable elbow, the rotatable elbow having a first end and a second end, the first end including a groove or recess provided to and engaging with the annular front flange of the ring-shaped member.

52. The mask system according to claim 47, wherein the frame further comprises a plurality of projecting frame ribs received within a portion of the flexible shell and cushion unit.

53. The mask system according to claim 47, wherein the frame includes at least one opening through which at least a portion of the shell portion extends.

54. The mask system according to claim 47, further comprising a plurality of vent holes provided in the shell portion.

55. The mask system according to claim 47, further comprising:

headgear attachment points formed on the frame, a first pair of the headgear attachment points being provided on a first side portion of the frame, and a second pair of the headgear attachment points being provided on a second side portion of the frame; and

wherein the headgear is adapted to be attached to the headgear attachment points, and the aperture of the shell portion is provided generally between the headgear attachment points.

56. The mask system according to claim 47, further comprising reinforcing ribs provided to the shell and cushion unit, wherein the reinforcing ribs have a greater thickness than adjacent portions of the shell and cushion unit.

57. The mask system according to claim 47, wherein the elbow is rotatable and has a first end and a second end, the first end adapted to engage with the ring-shaped member, and a swivel provided to the second end of the rotatable elbow, the swivel including a first end adapted to engage with the rotatable elbow, and the swivel having a second end adapted to engage an air delivery conduit.

58. The mask system according to claim 47, wherein the mask system does not have a forehead support.

59. The mask system according to claim 47, wherein the ring-shaped member and the frame are formed from a common material.

60. The mask system according to claim 47, wherein the ring-shaped member is separate from the frame.

61. The mask system according to claim 47, wherein the centrally located aperture of the shell portion is provided between headgear attachment points formed on the frame.

62. The mask system according to claim 47, wherein the frame is generally triangularly-shaped with rounded lower corners.

63. The mask system according to claim 47, wherein the centrally located aperture is disposed on a front face of the shell portion.

64. The mask system according to claim 47, wherein the at least one flange comprises a rear flange and a plurality of front flanges.