Mask with removable headgear connector

• US 9,937,315 B2
• Filed: 01/12/2015
• Issued: 04/10/2018
• Est. Priority Date: 01/30/2007
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Henry, Robert Edward
• Primary Examiner(s): DOUGLAS, STEVEN O
• Application Number:
  US14/594,284
• Publication Number:
  US 20150122254A1
• Time in Patent Office: 1,184 Days
• CPC Class Codes: A61M 16/0057 Pumps therefor
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• CPC Class Codes: A61M 16/0622 having an underlying cushion
• CPC Class Codes: A61M 16/0638 in the form of a pivot
• CPC Class Codes: A61M 16/0644 having the means for adjusting its position
• CPC Class Codes: A61M 16/065 in the form of a pivot
• 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 16/0833 T- or Y-type connectors, e.g. Y-piece
• CPC Class Codes: A62B 18/084 Means for fastening gas-masks to heads or helmets

Abstract

A mask for delivering breathable gas to a patient at positive pressure to treat sleep disordered breathing, may comprise: a rigid mask frame having a bore and an interfacing structure, the interfacing structure being located on the rigid mask frame and along a peripheral edge of the bore, said mask frame having no built-in or integral headgear attachment points; a sealing cushion provided to the rigid mask frame and adapted to form a seal with the patient'"'"'s face, the rigid mask frame and the sealing cushion together forming, at least partly, a breathing cavity; and a headgear connector adapted to engage the interfacing structure with a snap-fit, said headgear connector including a pair of lower headgear clip anchors adapted to be engaged with respective ones of a pair of tower headgear clips to attach a pair of lower side straps, said headgear connector including a fixed forehead support.

Claims

1. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame constructed of a substantially rigid, non-malleable plastic material, the mask frame having a bore and a curved interfacing structure, the bore having a cylindrical shape, the curved interfacing structure projecting from the bore in a radial direction, and said mask frame having no built-in or integral headgear attachment points;

a cushion provided to the mask frame and adapted to seal with the patient'"'"'s face in use;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a rear portion configured to cup the occiput of the patient'"'"'s head in use, and a pair of lower headgear clips adapted to receive respective ones of the pair of lower side straps;

an elbow assembly adapted to be connected to an air delivery tube to deliver the supply of air to the patient'"'"'s airways; and

a headgear connector adapted to engage the curved interfacing structure with a snap-fit, the headgear connector having a circular opening, said headgear connector including a pair of lower headgear clip anchors adapted to be engaged with respective ones of the pair of lower headgear clips to attach respective ones of the pair of lower side straps, said headgear connector including a fixed forehead support, said fixed forehead support including a pair of openings adapted to attach to respective ones of the pair of upper side straps,

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached.

2. The mask system according to claim 1, wherein:

the mask frame and the cushion comprise a nasal mask,

the cushion and the mask frame are permanently attached,

the mask system further comprises a vent for gas washout,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame,

the headgear connector is removably attachable to the mask frame,

said headgear connector is constructed of the substantially rigid, non-malleable plastic material, and

the mask frame includes a front surface facing away from the patient in use, the bore being located on the front surface of the mask frame.

3. A respiratory therapy system comprising:

the mask system according to claim 2;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

4. The mask system according to claim 2, wherein the curved interfacing structure has a circumferential extent that is greater than an axial thickness of the curved interfacing structure, and

wherein the curved interfacing structure is spaced from the front surface in an axial direction of the bore.

5. The mask system according to claim 1, wherein:

the mask frame and the cushion comprise a full-face mask,

the cushion and the mask frame are permanently attached,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame,

the headgear connector is removably attachable to the mask frame, and

said headgear connector is constructed of the substantially rigid, non-malleable plastic material, and

the mask frame includes a front surface facing away from the patient in use, the bore being located on the front surface of the mask frame.

6. A respiratory therapy system comprising:

the mask system according to claim 5;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

7. The mask system according to claim 5, wherein the curved interfacing structure has a circumferential extent that is greater than an axial thickness of the curved interfacing structure, and

wherein the curved interfacing structure is spaced from the front surface in an axial direction of the bore.

8. The mask system according to claim 5, wherein the mask frame further comprises a vent for gas washout.

9. The mask system according to claim 1, wherein the mask system further comprises a vent for gas washout.

10. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame having a bore and a curved interfacing structure, the curved interfacing structure projecting radially from the bore, the mask frame having no built-in or integral headgear attachment points;

a cushion provided to the mask frame and adapted to seal with the patient'"'"'s face;

an elbow assembly adapted to be connected to an air delivery tube to deliver the supply of air to the patient'"'"'s airways;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a rear portion configured to cup the occiput of the patient'"'"'s head in use, and a pair of lower headgear clips adapted to receive respective ones of the pair of lower side straps; and

a headgear connector having a circular, headgear connector opening, the headgear connector being adapted to engage the curved interfacing structure of the mask frame to removably connect the headgear connector to the mask frame, said bore and said headgear connector opening being concentrically disposed about a common axis when the headgear connector and the mask frame are connected,

wherein the mask frame and the headgear connector are constructed of a substantially rigid, non-malleable plastic material,

wherein the headgear connector and the mask frame are detachably connected together by translating the mask frame and the headgear connector towards one another along the common axis until a snap-fit connection is established between the headgear connector opening of the headgear connector and the curved interfacing structure of the mask frame,

wherein the headgear connector includes a pair of lower headgear clip receptacles adapted to be engaged with respective ones of the pair of lower headgear clips to attach respective ones of the pair of lower side straps,

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached, and

wherein said headgear connector includes a fixed forehead support, said fixed forehead support including a pair of upper openings adapted to attach to respective ones of the pair of upper side straps.

11. The mask system according to claim 10, wherein:

the mask frame and the cushion comprise a nasal mask

the cushion and the mask frame are permanently attached,

the mask system further comprises a vent for gas washout,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame,

the headgear connector is removably attachable to the mask frame,

the substantially rigid, non-malleable plastic material is polycarbonate, and

the mask frame includes a front surface facing away from the patient in use, the bore being located on the front surface of the mask frame.

12. A respiratory therapy system comprising:

the mask system according to claim 11;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

13. The mask system according to claim 11, wherein the curved interfacing structure has a circumferential extent that is greater than an axial thickness of the curved interfacing structure, and

wherein the curved interfacing structure is spaced from the front surface in an axial direction of the bore.

14. The mask system according to claim 10, wherein:

the mask frame and the cushion comprise a full-face mask,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame,

the substantially rigid, non-malleable plastic material is polycarbonate, and

the cushion and the mask frame are permanently attached,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame,

the headgear connector is removably attachable to the mask frame, and

the mask frame includes a front surface facing away from the patient in use, the bore being located on the front surface of the mask frame.

15. A respiratory therapy system comprising:

the mask system according to claim 14;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

16. The mask system according to claim 14, wherein the curved interfacing structure has a circumferential extent that is greater than an axial thickness of the curved interfacing structure, and

wherein the curved interfacing structure is spaced from the front surface in an axial direction of the bore.

17. The mask system according to claim 14, wherein the mask frame further comprises a vent for gas washout.

18. The mask system according to claim 10, wherein the mask system further comprises a vent for gas washout.

19. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame including a main body, the main body including a bore, and an interfacing structure;

a cushion provided to the mask frame and adapted to seal with the patient'"'"'s face;

an elbow assembly having a first end adapted to engage the mask frame at the bore and a second end adapted to be connected to an air delivery tube that delivers the supply of air to the patient;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a rear portion configured to cup the occiput of the patient'"'"'s head in use; and

a headgear connector including upper headgear attachment points structured to receive corresponding ones of the pair of upper side straps and lower headgear attachment points structured to receive corresponding ones of the pair of lower side straps,

wherein the headgear connector further comprises a plurality of tabs, each of the plurality of tabs configured to removably connect the headgear connector to the interfacing structure of the mask frame with a snap-fit,

wherein the headgear connector forms an opening having a closed perimeter and each of the plurality of tabs projects into the opening from an inner surface of the headgear connector that fully surrounds the opening,

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached, and

wherein the mask frame and the headgear connector are constructed of a substantially rigid, non-malleable plastic material.

20. The mask system according to claim 19, wherein:

the headgear connector further comprises a fixed forehead support,

the plurality of tabs further comprises;

a pair of upper tabs, each of the pair of upper tabs positioned on a corresponding lateral side of the mask frame, and

a pair of lower tabs, each of the pair of lower tabs positioned on a corresponding lateral side of the mask frame,

the mask frame and the cushion comprise a full-face mask,

the cushion is secured to the mask frame,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame, and

wherein the substantially rigid, non-malleable plastic material is polycarbonate.

21. A respiratory therapy system comprising:

the mask system according to claim 20;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

22. The mask system according to claim 19, wherein:

the plurality of tabs further comprises;

a pair of upper tabs, each of the pair of upper tabs positioned on a corresponding lateral side of the mask frame, and

a pair of lower tabs, each of the pair of lower tabs positioned on a corresponding lateral side of the mask frame,

the mask frame and the cushion comprise a full-face mask,

the cushion is secured to the mask frame,

at least a portion of said headgear connector is shaped to conform to a portion of said mask frame, and

wherein the substantially rigid, non-malleable plastic material is polycarbonate.

23. The mask system according to claim 20, further comprising a pair of rigidizers configured to improve stability of the mask system in use, each of the pair of rigidizers constructed of a rigid material or a semi-rigid material, and each of the pair of rigidizers being provided to a corresponding lateral side of the headgear connector such that each of the pair of rigidizers passes between corresponding ones of the patient'"'"'s eyes and ears in use.

24. The mask system according to claim 20, wherein the mask frame further comprises a vent for gas washout.

25. A respiratory therapy system comprising:

the mask system according to claim 20;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

26. A respiratory therapy system comprising:

the mask system according to claim 22;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

27. The mask system according to claim 22, further comprising a pair of rigidizers configured to improve stability of the mask system in use, each of the pair of rigidizers constructed of a rigid material or a semi-rigid material, and each of the pair of rigidizers being provided to a corresponding lateral side of the headgear connector such that each of the pair of rigidizers passes between corresponding ones of the patient'"'"'s eyes and ears in use.

28. The mask system according to claim 22, wherein the mask frame further comprises a vent for gas washout.

29. The mask system according to claim 19, wherein the mask system further comprises a vent for gas washout.

30. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame constructed of a substantially rigid, non-malleable plastic material, the mask frame having a bore and an interfacing structure, the bore having a cylindrical shape and a first longitudinal axis, the interfacing structure projecting from around the bore in a radial direction relative to the first longitudinal axis and having a circular shape, and said mask frame having no built-in or integral headgear attachment points;

a cushion secured to the mask frame and adapted to seal with the patient'"'"'s face in use, the cushion and the mask frame at least partly forming a breathing cavity;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a rear portion configured to cup the occiput of the patient'"'"'s head in use;

an elbow assembly adapted to be connected to an air delivery tube to deliver the supply of air to the breathing cavity for inhalation by the patient;

a vent for gas washout; and

a headgear connector adapted to detachably engage the interfacing structure with a snap-fit such that the headgear connector is removably attachable to the mask frame, the headgear connector having a circular opening, and said headgear connector including;

a pair of upper attachment points, each of the pair of upper attachment points including an upper opening configured to receive a corresponding one of the pair of upper side straps passed through the upper opening to removably connect the headgear to the headgear connector; and

a pair of lower attachment points, each of the pair of lower attachment points including a lower opening configured to receive a corresponding one of the pair of lower side straps passed through the lower opening to removably connect the headgear to the headgear connector,

wherein at least a portion of said headgear connector is shaped to conform to a portion of said mask frame, and

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached.

31. The mask system according to claim 30, wherein the headgear connector includes a fixed forehead support.

32. The mask system according to claim 30, wherein:

the mask frame and the cushion comprise a full-face mask,

the headgear connector is constructed of the substantially rigid, non-malleable plastic material,

the circular opening has a second longitudinal axis,

the cushion and the mask frame are permanently attached,

the mask frame includes a front surface facing away from the patient in use, the bore being located on the front surface of the mask frame, and

the headgear connector and the mask frame are detachably connected together by translating the mask frame and the headgear connector towards one another until the snap-fit is established between the headgear connector and the interfacing structure of the mask frame such that the first longitudinal axis and the second longitudinal axis are coaxial.

33. The mask system according to claim 32, further comprising a pair of lower headgear clips provided to corresponding ones of the pair of lower side straps, and

wherein the headgear connector further comprises a pair of lower headgear clip receptacles adapted to be engaged with respective ones of the pair of lower headgear clips.

34. A respiratory therapy system comprising:

the mask system according to claim 32;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

35. The mask system according to claim 32, further comprising a pair of rigidizers, each of the pair of rigidizers attached to a corresponding one of the pair of upper side straps.

36. A respiratory therapy system comprising:

the mask system according to claim 30;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

37. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame including a main body, the main body including a circular bore, and an interfacing structure;

a cushion provided to the mask frame and adapted to seal with the patient'"'"'s face;

an elbow assembly having a first end adapted to engage the mask frame at the circular bore and a second end adapted to be connected to an air delivery tube that delivers the supply of air to the patient;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, and a rear portion configured to cup the occiput of the patient'"'"'s head in use; and

a headgear connector including upper headgear attachment points structured to receive corresponding ones of the pair of upper side straps and lower headgear attachment points structured to receive corresponding ones of the pair of lower side straps via clips,

wherein the headgear connector further comprises a plurality of tabs, each of the plurality of tabs configured to removably connect the headgear connector to the interfacing structure of the mask frame with a snap-fit,

wherein the headgear connector forms an opening having a closed perimeter and each of the plurality of tabs projects into the opening from an inner surface of the headgear connector that fully surrounds the opening,

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached, and

wherein the mask frame is constructed of a substantially rigid, non-malleable plastic material.

38. The mask system according to claim 37, wherein the headgear connector further comprises a fixed forehead support.

39. The mask system according to claim 37, wherein:

the interfacing structure is not continuous around the mask frame,

the mask frame further comprises a vent for gas washout,

the mask frame and the cushion comprise a full-face mask,

the cushion is secured to the mask frame, and

the substantially rigid, non-malleable plastic material is polycarbonate.

40. A respiratory therapy system comprising:

the mask system according to claim 39;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

41. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame including a main body with an aperture centered at a longitudinal axis, the main body including an annular member extending from the main body parallel to the longitudinal axis and positioned radially outward relative to the aperture, the annular member having a distal end opposite the main body relative to the longitudinal axis, the annular member having an engagement structure extending radially outward from the annular member at the distal end, and the annular member having a circumferential surface extending parallel to the longitudinal axis and positioned between the engagement structure and the main body, the mask frame having no built-in or integral headgear attachment points;

a cushion provided to the mask frame and adapted to seal with the patient'"'"'s face;

an elbow assembly having a first end engaged with the mask frame and a second end adapted to be connected to an air delivery tube to deliver the supply of air to the patient;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a clip provided to each of the lower side straps, and a rear portion configured to cup the occiput of the patient'"'"'s head in use; and

a headgear connector including a headgear connector opening having a closed perimeter, a pair of upper openings structured to receive a corresponding one of the upper side straps to attach the upper side straps to the headgear connector, and a pair of lower headgear clip receptacles structured to receive a corresponding one of the clips to attach the lower side straps to the headgear connector,

wherein the headgear connector is configured to removably connect to the engagement structure of the mask frame with a snap-fit at the headgear connector opening,

wherein the annular member extends into the headgear connector opening when the headgear connector is removably connected to the mask frame,

wherein the mask frame is constructed of a substantially rigid, non-malleable plastic material,

wherein at least a portion of said headgear connector is shaped to conform to a portion of said mask frame, and

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached.

42. The mask system according to claim 41, wherein the headgear connector further comprises a fixed forehead support.

43. The mask system according to claim 41, wherein:

the engagement structure is not continuous around the mask frame,

the mask frame further comprises a vent for gas washout,

the mask frame and the cushion comprise a full-face mask,

the cushion is secured to the mask frame, and

the substantially rigid, non-malleable plastic material is polycarbonate.

44. A respiratory therapy system comprising:

the mask system according to claim 43;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.

45. A mask system for delivering a supply of air generated by a flow generator at a positive pressure in a therapeutic range to a patient'"'"'s airways to treat sleep disordered breathing, the mask system comprising:

a mask frame constructed of a substantially rigid, non-malleable plastic material, the mask frame having a bore and an interfacing structure that is proximate to the bore, the bore having a cylindrical shape and a first longitudinal axis, the interfacing structure projecting in an outward, radial direction relative to the first longitudinal axis, the mask frame having a front surface associated therewith, the mask frame further having a circumferential, outer surface that is spaced from the bore and that extends from the front surface to the interfacing structure, the circumferential, outer surface being parallel to the first longitudinal axis, and said mask frame having no built-in or integral headgear attachment points;

a cushion secured to the mask frame and adapted to seal with the patient'"'"'s face in use, the cushion and the mask frame at least partly forming a breathing cavity;

headgear including a pair of upper side straps configured to extend above the patient'"'"'s ears in use, a pair of lower side straps configured to extend below the patient'"'"'s ears in use, a clip provided to each of the lower side straps, and a rear portion configured to cup the occiput of the patient'"'"'s head in use;

an elbow assembly adapted to be connected to an air delivery tube to deliver the supply of air to the breathing cavity for inhalation by the patient; and

a headgear connector adapted to detachably engage the interfacing structure with a snap-fit such that the headgear connector is removably attachable to the mask frame, the headgear connector having a headgear connector opening having a closed perimeter, said headgear connector including;

a pair of upper attachment points, each of the pair of upper attachment points including an upper opening configured to receive a corresponding one of the pair of upper side straps passed through the upper opening to removably connect the headgear to the headgear connector; and

a pair of lower headgear clip receptacles configured to receive a corresponding one of the clips to removably connect the headgear to the headgear connector,

wherein at least a portion of said headgear connector is shaped to conform to a portion of said mask frame, and

wherein the mask frame and the headgear connector are constructed to resist movement between the mask frame and the headgear connector when said mask frame and said headgear connector are attached.

46. The mask system according to claim 45, wherein the headgear connector further comprises a fixed forehead support.

47. The mask system according to claim 45, wherein:

the interfacing structure is not continuous around the mask frame,

the mask frame further comprises a vent for gas washout,

the mask frame and the cushion comprise a full-face mask,

the cushion is secured to the mask frame, and

the substantially rigid, non-malleable plastic material is polycarbonate.

48. A respiratory therapy system comprising:

the mask system according to claim 47;

a flow generator configured to generate a supply of air at a positive pressure in a therapeutic range; and

an air delivery tube connected to the elbow assembly to deliver the supply of air from the flow generator to the mask system to provide the supply of air to the patient.