Respiratory apparatus

• US 10,987,477 B2
• Filed: 11/16/2016
• Issued: 04/27/2021
• Est. Priority Date: 02/04/2013
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Inventors: Law, Kam Man, Scheiner, Rupert Christian, Wells, Matthew Robin, Eves, Matthew, Nga, Lemmy, Rummery, Gerard Michael, Day, Shannon, Guney, Memduh
• Primary Examiner(s): Yao, Samchuan C
• Assistant Examiner(s): Le, Nathan M
• Application Number:
  US15/353,396
• Publication Number:
  US 20170128689A1
• Time in Patent Office: 1,623 Days
• CPC Class Codes: A61M 16/0066 Blowers or centrifugal pumps
• CPC Class Codes: A61M 16/0069 the speed thereof being controlled by respiratory parameters, e.g. by inhalation
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• CPC Class Codes: A61M 16/0605 Means for improving the adaptation of the mask to the patient
• 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 16/0666 Nasal cannulas or tubing devices for improving normal breathing through the nose A61F5/08; nose filters A62B23/06; outside holding devices A61M25/02
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0825 with ball-sockets
• CPC Class Codes: A61M 16/0875 Connecting tubes
• CPC Class Codes: A61M 16/1055 bacterial
• CPC Class Codes: A61M 16/107 in the inspiratory path
• CPC Class Codes: A61M 16/109 the humidifying liquid or the beneficial agent
• CPC Class Codes: A61M 16/1095 in the connecting tubes
• CPC Class Codes: A61M 16/16 Devices to humidify the respiration air A61M16/1045 takes precedence
• CPC Class Codes: A61M 2202/0225 Carbon oxides, e.g. Carbon dioxide
• CPC Class Codes: A61M 2205/42 Reducing noise
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: A61M 2210/0618 Nose
• CPC Class Codes: A61M 2210/0625 : Mouth

Abstract

A mask apparatus for a respiratory treatment can permit delivery of breathable gas to a user. In one example, the mask may employ a frame and cushion to form a seal for both mouth and nose. The frame may be adapted for coupling with a respiratory treatment apparatus so as to permit communication of a pressurized gas from the respiratory treatment apparatus. The cushion, which may be foam, may have a substantially under the nose configuration or over the nose configuration. The mask may have a common plenum chamber for both nose and mouth. The cushion may further define a centrally open lip superior region. The cushion may be adapted to couple with the frame directly or to the frame in conjunction with a cushion support clip. Various features of the cushion may further promote sealing and comfort for the under the nose design.

Claims

1. A foam cushion assembly for a patient interface for providing a pressurised air to a user'"'"'s airway, the foam cushion assembly comprising:

a foam cushion portion configured to, in use, seal around portion of the user'"'"'s nose; and

a flexible support portion extending along a periphery of the foam cushion portion so as to support the foam cushion portion,

wherein the foam cushion portion has a trapezium cross sectional shape in at least a side of nose region and comprises;

(a) a sealing surface including at least a portion thereof at a first side of the trapezium cross sectional shape, the at least a portion of the sealing surface including a radially flat region for user facial contact at the first side, and (b) a fixing surface side of the trapezium cross sectional shape, the fixing surface side being opposite to the first side and comprising a planar surface for adhering to a surface of the flexible support portion,

wherein the sealing surface has a three-dimensional surface contour arranged so that the radially flat region in at least a portion of the sealing surface'"'"'s periphery is inwardly inclined, with respect to a mid-contact plane of the patient interface, for embracing and conforming to a shape of the user'"'"'s face in use,

wherein the sealing surface includes a portion for sealing above a pronasale portion of the user'"'"'s nose in use,

wherein the radially flat region is in both of a side of mouth region and a side of nose region,

wherein the three-dimensional surface contour is radially flat about the sealing surface'"'"'s periphery in both side of mouth regions, both side of nose regions and a bottom region,

wherein the least a portion of the sealing surface includes a planar surface region, wherein the three-dimensional surface contour is arranged so that the planar surface region in the at least a portion of the sealing surface'"'"'s periphery is inwardly inclined, with respect to the mid-contact plane of the patient interface, for embracing and conforming to the shape of the user'"'"'s face in use, and

wherein the foam cushion assembly is arranged to seal around a portion of the user'"'"'s mouth in use and wherein the three-dimensional surface contour comprises side of mouth planar regions.

2. The foam cushion assembly of claim 1, wherein the three-dimensional surface contour is radially flat about the entire sealing surface'"'"'s periphery.

3. The foam cushion assembly of claim 1, wherein the sealing surface includes a first planar sealing surface region and a second planar sealing surface region on respective sides of a sagittal plane of the foam cushion, the first planar sealing surface region and the second planar sealing surface region being inwardly inclined with respect to the mid-contact plane of the foam cushion assembly.

4. The foam cushion assembly of claim 3, wherein planes parallel to the planar sealing surface regions at each side of the sagittal plane form an angle in a range of 70 to 110 degrees.

5. The foam cushion assembly of claim 3, wherein the first planar sealing surface region is a side of nose planar region.

6. The foam cushion assembly of claim 3, wherein the planar sealing surface regions are at both sides of the user'"'"'s nose in use and form an angle of 75 to 95 degrees.

7. The foam cushion assembly of claim 1, wherein a side of mouth planar region of the side of mouth planar regions of the three-dimensional surface contour is co-planar with a side of nose planar region of the three-dimensional surface contour.

8. The foam cushion assembly of claim 5, wherein the second planar sealing surface region is a side of mouth planar region.

9. The foam cushion assembly of claim 8, wherein a plane parallel to the first planar sealing surface at a side of nose region and a plane parallel to the second planar sealing surface at a side of mouth region on an opposing side of the mid-contact plane form a second angle in a range of 70 to 110 degrees.

10. The foam cushion assembly of claim 9, wherein the second angle is an angle of 80-100 degrees.

11. The foam cushion assembly of claim 1, wherein the three-dimensional surface contour of the sealing surface extends along an entire periphery of a plenum chamber.

12. The foam cushion assembly of claim 11, wherein at least a portion of the foam cushion at the trapezium cross sectional shape is formed with rounded corners on each opposing side of the at least a portion of the sealing surface.

13. The foam cushion assembly of claim 12, wherein the planar surface region of the sealing surface has a sealing width in a radial direction at the both sides of nose regions in a range of 8 to 12 mm.

14. The foam cushion assembly of claim 13, wherein a sealing surface of the three-dimensional surface contour comprises a cresting surface region near a nasal bridge region, the cresting surface region being characterised by a region of negative curvature flanked by adjacent regions of positive curvature to define a surface rise increasing in a normal direction from the sealing surface of the three-dimensional surface contour, flanked by adjacent surface decreases in an anti-normal direction.

15. The foam cushion assembly of claim 14, wherein the cresting surface region in the cushion assembly is imparted onto the cushion by the flexible support portion.

16. The foam cushion assembly of claim 14, wherein each of the cresting surface regions forms a bulbous contour portion on a respective side of the sagittal plane of the foam cushion assembly.

17. The foam cushion assembly of claim 14, wherein the cresting surface regions decrease into a part-conical depression of the nasal bridge region of the foam cushion assembly defined by generally small positive curvatures in both radial and peripheral direction.

18. The foam cushion assembly of claim 1, wherein the three-dimensional surface contour of the foam cushion comprises a conical depression at a nasal bridge region.

19. The foam cushion assembly of claim 18, wherein a rounded ridge forms a semi-peripheral boundary about the conical depression.

20. The foam cushion assembly of claim 19, wherein the peripheral boundary of the rounded ridge forms a semi-circular periphery in a range of 140 to 220 degrees about the generally conical depression.

21. The foam cushion assembly of claim 19, wherein the rounded ridge of the semi-peripheral boundary about the conical depression extends into a rounded corner edge of the surface of a planar sealing surface region or a cresting sealing surface region.

22. The foam cushion assembly of claim 1, wherein a portion of the sealing surface of the three-dimensional surface contour in the bottom of mouth region forms a semi-cylindrical surface between both sides of mouth regions.

23. The foam cushion assembly of claim 1, wherein the flexible support portion comprises a membrane attached to the foam cushion portion that imparts at least a portion of the three-dimensional surface contour to the foam cushion by creating bend regions of foam compression in different regions along the periphery.

24. The foam cushion assembly of claim 1, wherein the foam cushion assembly further comprises a rigid shell with a plenum chamber, the rigid shell coupled to the flexible support portion.

25. The foam cushion assembly of claim 22, wherein a membrane of the flexible support portion is more flexible in a nasal bridge region than in the bottom of mouth region.

26. The foam cushion assembly of claim 23, wherein the flexible support portion comprises a flexible buttress approximately perpendicular to the surface of the membrane of the flexible support portion, the flexible buttress supporting at least one of the both sides of nose regions of the foam cushion assembly in use.

27. The foam cushion assembly of claim 26, wherein the buttress supports the cushion in a cresting surface region near a nasal bridge region.

28. The foam cushion assembly of claim 23, wherein the fixing surface of the foam cushion is planar and the three-dimensional sealing surface contour of the foam cushion are separated by a generally constant foam thickness about its perimeter in the both sides of nose regions, the both sides of mouth regions and the bottom of mouth region.

29. The foam cushion assembly of claim 1, wherein the foam cushion portion is arranged to directly contact the user'"'"'s face in use.

30. The foam cushion assembly of claim 1, wherein the three-dimensional surface contour of the bottom of mouth region has an edge in a cross-section made by a sagittal plane of the foam cushion assembly that is parallel to the mid-contact plane of the foam cushion assembly.

31. The foam cushion assembly of claim 1, wherein the foam cushion has a rectangular or square shape along at least a portion of its periphery.

32. The foam cushion assembly of claim 1, wherein the three-dimensional surface contour of the sealing surface of the foam cushion comprises one or more of:

the bottom of mouth region characterized by a small positive curvature surface in a peripheral direction and zero curvature in a radial direction;

the both sides of mouth regions on both sides of a sagittal plane, which are flat surfaces in both the radial and the peripheral directions;

the both sides of nose regions on both sides of the sagittal plane, which are flat in both the radial and the peripheral directions;

cresting surface regions, near a nasal bridge region, on both sides of the sagittal plane that are characterized by a relatively small negative curvature surface flanked on both sides by relatively small positive curvature surfaces; and

the nasal bridge region characterized by a relatively large positive curvature surface in the peripheral direction, and a relatively small positive curvature surface in the radial direction.

33. The foam cushion assembly of claim 1, wherein a surface contour of an outer surface side of the foam cushion comprises one or more of:

the bottom of the mouth region characterized by a relatively small negative curvature surface and a central portion near the sagittal plane being a relatively flat surface;

the both sides of the mouth regions characterized by a relatively large negative curvature that tapers down towards a lower side of nose region,

a relatively small positive curvature surface transition from the lower-to-mid nose regions to the upper side of nose and nasal bridge regions; and

a large negative curvature surface of a radius of about 10 to 20 mm in an outer side of a part-conical surface depression region.

34. The foam cushion assembly of claim 33, wherein a surface contour of an inner surface side comprises a mirror image of the surface of the outer surface side, with curvatures of opposite signs.

35. The foam cushion assembly of claim 1, wherein the sealing surface of the foam cushion at both right and left sides of a sagittal plane are tilted strictly towards the sagittal plane.

36. The foam cushion assembly of claim 35, wherein the sealing surface of the foam cushion at both right and left sides are tilted symmetrically relative to the sagittal plane.