U.S. patent application number 13/964280 was filed with the patent office on 2014-12-25 for mask system.
The applicant listed for this patent is ResMed Limited. Invention is credited to Errol Savio Alex D'SOUZA, Matthew EVES, David James LOCKWOOD, Eva NG, Mahsita SARI, Zoran VALCIC, Jamie Graeme WEHBEH.
Application Number | 20140373847 13/964280 |
Document ID | / |
Family ID | 41055474 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140373847 |
Kind Code |
A2 |
NG; Eva ; et al. |
December 25, 2014 |
MASK SYSTEM
Abstract
A full-face mask system for delivery of a supply of gas at
positive pressure to a patient for medical treatment includes a
shroud, a cushion module adapted to form a seal with the patient's
nose and mouth, an elbow, and headgear. The cushion module includes
a frame and a cushion. The frame includes an opening that
releasably receives a distal end of the elbow with a snap-fit,
wherein an inner edge of the opening and the distal end of the
elbow together form a retention structure to retain the elbow to
the frame.
Inventors: |
NG; Eva; (Erskineville,
AU) ; LOCKWOOD; David James; (Seaford, AU) ;
WEHBEH; Jamie Graeme; (Mosman, AU) ; VALCIC;
Zoran; (Chatswood, AU) ; D'SOUZA; Errol Savio
Alex; (Hornsby Heights, AU) ; EVES; Matthew;
(Manly Vale, AU) ; SARI; Mahsita; (Kensington,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ResMed Limited |
Bella Vista, New South Wales |
|
AU |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130327333 A1 |
December 12, 2013 |
|
|
Family ID: |
41055474 |
Appl. No.: |
13/964280 |
Filed: |
August 12, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13745077 |
Sep 10, 2013 |
8528561 |
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13964280 |
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12736024 |
Oct 8, 2013 |
8550084 |
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PCT/AU2009/000241 |
Feb 27, 2009 |
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13745077 |
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61064406 |
Mar 4, 2008 |
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61071893 |
May 23, 2008 |
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61136617 |
Sep 19, 2008 |
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Current U.S.
Class: |
128/205.25 |
Current CPC
Class: |
A61M 16/0694 20140204;
A61M 16/06 20130101; A61M 16/0825 20140204; A61M 16/0875 20130101;
A61M 16/20 20130101; A61M 16/0066 20130101; A61M 16/0816 20130101;
A61M 16/0841 20140204; A61M 16/0633 20140204; A61M 16/0616
20140204; A61M 16/0057 20130101; A61M 16/0622 20140204; A61M
16/0611 20140204; A61M 16/0683 20130101; A61M 16/0858 20140204;
A61M 2016/0661 20130101 |
Class at
Publication: |
128/205.25 |
International
Class: |
A61M 16/06 20060101
A61M016/06; A61M 16/00 20060101 A61M016/00 |
Claims
1-90. (canceled)
91. A mask system comprising: (i) headgear; (ii) an elbow; (iii) a
cushion module comprising a cushion constructed of a relatively
soft elastomeric material to form a seal with a patient's face in
use, a frame constructed of a relatively rigid material, said frame
defining a breathing chamber, the frame including a protruding vent
arrangement having a plurality of holes, the cushion and the frame
structured to be a one-piece, integrated component; and (iv) a
shroud including a pair of upper headgear connectors and a pair of
lower headgear connectors, said upper headgear connectors and said
lower headgear connectors structured to connect to said headgear,
wherein the shroud includes a first opening to accommodate said
protruding vent arrangement, further wherein the shroud includes a
second opening to accommodate the elbow, and further wherein the
shroud includes a retaining portion structured to removably retain
the frame to allow the cushion module to be replaced.
92. The mask system of claim 91 wherein the frame includes an
opening and the frame further includes a collar surrounding said
opening.
93. The mask system of claim 92 wherein the retaining portion
includes one or more snap fingers structured to engage the collar
with a snap-fit.
94. The mask system of claim 91 wherein retaining portion of the
shroud includes an annular retaining portion structured to retain
the frame, and the lower headgear connectors are positioned on each
side of the retaining portion.
95. The mask system of claim 91 wherein the retaining portion, the
upper headgear connectors and the lower headgear connectors are
formed as a one piece structure.
96. The mask system of claim 91 wherein the shroud is integrally
formed in one piece.
97. The mask system of claim 91 wherein the cushion is constructed
to engage along a nasal bridge region, a cheek region, and a lower
lip/chin region of the patient's face when in use.
98. The mask system of claim 91 wherein the cushion comprises
silicone.
99. The mask system of claim 98 wherein the silicone comprises
frosted silicone.
100. The mask system of claim 91 wherein the frame is constructed
to receive a patient's nose and mouth and provide air communication
to the patient when in use.
101. The mask system of claim 91 wherein the cushion and the frame
are constructed and arranged to be in an interlocking relationship
with one another.
102. The mask system of claim 91 wherein the cushion includes one
or more positioning features located around its circumference to
assist with alignment of the cushion with the frame.
103. The mask system of claim 91 wherein the cushion includes
notches and/or protrusions to engage with complementary features in
the frame.
104. The mask system of claim 91 wherein the cushion is co-moulded
to the frame.
105. The mask system of claim 91 wherein the frame comprises
polycarbonate.
106. The mask system of claim 91 wherein said headgear comprises
hook and loop material.
107. The mask system of claim 91 further comprising a forehead
support.
108. The mask system of claim 91 further comprising an air delivery
tube.
109. The mask system of claim 91, wherein the cushion is a
full-face cushion.
110. The mask system of claim 91 wherein the elbow includes an
anti-asphyxia valve.
111. The mask system of claim 91 wherein: the frame includes an
opening and the frame further includes a collar surrounding said
opening, the retaining portion includes one or more snap fingers
structured to engage the collar with a snap-fit, the retaining
portion, the upper headgear connectors and the lower headgear
connectors are formed as a one piece structure, the shroud is
integrally formed in one piece, the cushion is constructed to
engage along a nasal bridge region, a cheek region, and a lower
lip/chin region of the patient's face when in use, the cushion
comprises frosted silicone, the frame is constructed to receive a
patient's nose and mouth and provide air communication to the
patient when in use, the cushion and the frame are constructed and
arranged to be in an interlocking relationship with one another,
the cushion includes one or more positioning features located
around its circumference to assist with alignment of the cushion
with the frame, the cushion includes notches and/or protrusions to
engage with complementary features in the frame, the cushion is
co-moulded to the frame, the frame comprises polycarbonate, said
headgear comprises hook and loop material, the shroud further
comprises a forehead support, the cushion is a full-face cushion,
and the elbow includes an anti-asphyxia valve.
112. A mask system comprising: (i) headgear; (ii) an elbow; (iii) a
cushion module comprising a cushion constructed of a relatively
soft elastomeric material to form a seal with a patient's face in
use, a frame constructed of a relatively rigid material, said frame
defining a breathing chamber, the frame including a protruding vent
arrangement having a plurality of holes, the cushion and the frame
structured to be a one-piece, integrated component; and (iv) a
shroud to removably retain the frame, the shroud including headgear
connectors structured to connect to said headgear, wherein the
shroud includes a first opening to accommodate said protruding vent
arrangement, and wherein the shroud includes a second opening to
accommodate the elbow.
113. The mask system of claim 112 wherein the frame includes an
opening and the frame further includes a collar surrounding said
opening.
114. The mask system of claim 113 wherein the shroud includes one
or more snap fingers structured to engage the collar with a
snap-fit.
115. The mask system of claim 112 wherein the shroud includes an
annular retaining portion structured to retain the frame and upper
and lower headgear connectors on each side of the retaining
portion.
116. The mask system of claim 112 wherein the shroud is integrally
formed in one piece.
117. The mask system of claim 112 wherein the cushion is
constructed to engage along a nasal bridge region, a cheek region,
and a lower lip/chin region of the patient's face when in use.
118. The mask system of claim 112 wherein the cushion comprises
silicone.
119. The mask system of claim 118 wherein the silicone comprises
frosted silicone.
120. The mask system of claim 112 wherein the frame is constructed
to receive a patient's nose and mouth and provide air communication
to the patient when in use.
121. The mask system of claim 112 wherein the cushion and the frame
are constructed and arranged to be in an interlocking relationship
with one another.
122. The mask system of claim 112 wherein the cushion includes one
or more positioning features located around its circumference to
assist with alignment of the cushion with the frame.
123. The mask system of claim 112 wherein the cushion includes
notches and/or protrusions to engage with complementary features in
the frame.
124. The mask system of claim 112 wherein the cushion is co-moulded
to the frame.
125. The mask system of claim 112 wherein the frame comprises
polycarbonate.
126. The mask system of claim 112 wherein said headgear comprises
hook and loop material.
127. The mask system of claim 112 further comprising a forehead
support.
128. The mask system of claim 112 further comprising an air
delivery tube.
129. The mask system of claim 112, wherein the cushion is a
full-face cushion.
130. The mask system of claim 112 wherein the elbow includes an
anti-asphyxia valve.
131. The mask system of claim 112 wherein: the frame includes an
opening and the frame further includes a collar surrounding said
opening, the shroud includes one or more snap fingers structured to
engage the collar with a snap-fit, the shroud is integrally formed
in one piece, the cushion is constructed to engage along a nasal
bridge region, a cheek region, and a lower lip/chin region of the
patient's face when in use, the cushion comprises frosted silicone,
the frame is constructed to receive a patient's nose and mouth and
provide air communication to the patient when in use, the cushion
and the frame are constructed and arranged to be in an interlocking
relationship with one another, the cushion includes one or more
positioning features located around its circumference to assist
with alignment of the cushion with the frame, the cushion includes
notches and/or protrusions to engage with complementary features in
the frame, the cushion is co-moulded to the frame, the frame
comprises polycarbonate, said headgear comprises hook and loop
material, the shroud further comprises a forehead support, the
cushion is a full-face cushion, and the elbow includes an
anti-asphyxia valve.
132. Apparatus for treating sleep disordered breathing comprising a
flow generator and the mask system as claimed in claim 91.
133. Apparatus for treating sleep disordered breathing comprising a
flow generator and the mask system as claimed in claim 112.
134. A mask system comprising: (i) a cushion module comprising a
frame constructed of a relatively rigid material, said frame
defining a breathing chamber, the frame including a protruding vent
arrangement having a plurality of vent holes, the frame including a
frame opening configured to in-use allow a flow of breathable gas
into the breathing chamber for patient breathing, and a cushion
constructed of a relatively soft elastomeric material to form a
seal with a patient's face in use, and wherein the cushion is
connected to the frame; and (ii) a shroud structured to removably
retain the frame of the cushion module, wherein the shroud includes
a first opening to accommodate said protruding vent arrangement,
further wherein the shroud includes a second opening configured to
in use cooperate with the frame opening to allow a flow of
breathable gas into to the breathing chamber for patient breathing,
and (iii) headgear connected to the shroud.
135. The mask system of claim 134, wherein the frame includes a
collar surrounding said frame opening, said collar being structured
to receive a retaining portion of the shroud.
136. The mask system of claim 135, wherein the retaining portion
includes one or more snap fingers structured to engage the collar
with a snap-fit.
137. The mask system of claim 134, wherein the shroud includes an
annular retaining portion structured to engage with a corresponding
structure on the frame to thereby removably retain the frame.
138. The mask system of claim 134, further comprising a pair of
upper headgear connectors and a pair of lower headgear
connectors.
139. The mask system of claim 138, wherein the lower headgear
connectors are positioned on each side of the shroud.
140. The mask system of claim 138, wherein the upper headgear
connectors are moulded to the shroud.
141. The mask system of claim 138, wherein the lower headgear
connectors are moulded to the shroud.
142. The mask system of claim 134, wherein the shroud is formed to
be a one-piece component.
143. The mask system of claim 134, wherein the cushion is
constructed to engage along a nasal bridge region, a cheek region,
and a lower lip or chin region of the patient's face when in
use.
144. The mask system of claim 134, wherein the breathing chamber is
constructed to receive a patient's nose and mouth.
145. The mask system of claim 134, wherein the mask system is a
full-face mask system.
146. The mask system of claim 134, wherein the cushion comprises
silicone.
147. The mask system of claim 146, wherein the cushion comprises
frosted silicone.
148. The mask system of claim 134, wherein the connection of the
cushion and the frame to each other is an interlocking
relationship.
149. The mask system of claim 134, wherein the cushion includes one
or more positioning features located around its circumference to
assist with alignment of the cushion with the frame.
150. The mask system of claim 134, wherein the cushion includes
notches and/or protrusions to engage with complementary features in
the frame.
151. The mask system of claim 134, wherein the connection of the
cushion to the frame is co-moulding.
152. The mask system of claim 134, wherein the frame comprises
polycarbonate.
153. The mask system of claim 134, further comprising headgear
connectors to attach the headgear to said shroud.
154. The mask system of claim 153, wherein the headgear is
removably attached to the shroud.
155. The mask system of claim 154, wherein the headgear is
removably attached to said shroud by hook and loop connectors which
engage the headgear connectors.
156. The mask system of claim 134, wherein said shroud further
comprises a forehead support.
157. The mask system of claim 134, further comprising an air
delivery tube connected to the second opening in the shroud.
158. The mask system of in claim 157, wherein the air delivery tube
is connected to the second opening by an elbow.
159. The mask system of claim 157, wherein the elbow comprises an
interfacing structure configured to interface with or otherwise
attach the elbow in the second opening.
160. The mask system of claim 159, wherein the elbow is configured
to allow rotation or swivelling of the elbow.
161. The mask system of claim 159, wherein the interfacing
structure permits the elbow to rotate through 360.degree..
162. The mask system of claim 159, wherein the elbow comprises a
first end, a second end, and a swivel joint provided to the second
end that is adapted to be connected to an air delivery tube.
163. The mask system of claim 162, further comprising an air
delivery tube that is connected to the swivel joint.
164. The mask system of claim 134, comprising an anti-asphyxia
valve.
165. The mask system of claim 164, wherein the anti-asphyxia valve
comprises a port and a flap portion to selectively close said
port.
166. The mask system of claim 165, wherein the flap portion and the
clip portion are co-moulded with one another.
167. The mask system of claim 164, wherein the anti-asphyxia valve
comprises a clip portion that is configured to attach the valve to
an elbow.
168. A shroud for a mask system, wherein the shroud comprises a
first opening to in use accommodate a protruding vent arrangement
of a cushion module, and a second opening to allow a flow of
breathable gas into a breathing chamber of the cushion module, and
a retaining portion structured to removably retain a frame of a
cushion module to allow the cushion module to be replaced.
169. The shroud of claim 168, wherein the retaining portion
includes one or more snap fingers structured to engage the frame
with a snap-fit.
170. The shroud of claim 168, wherein the retaining portion
includes an annular retaining portion structured to retain the
frame.
171. The shroud of claim 168, including a pair of upper headgear
connectors and a pair of lower headgear connectors, said upper
headgear connectors and said lower headgear connectors structured
to connect to a headgear.
172. The shroud of claim 171, wherein the lower headgear connectors
are positioned on each side of the retaining portion.
173. The shroud of claim 171, comprising an air delivery tube
provided in to the second opening.
174. The shroud of claim 173, wherein the air delivery tube is
connected to the second opening by an elbow.
175. The shroud of claim 174, wherein the elbow comprises
interfacing structure configured to moveably interface with or
otherwise attach the elbow in the second opening.
176. The shroud of claim 175 wherein the interfacing structure is
configured to permit the elbow to rotate or swivel with respect to
the frame when the elbow is attached to the frame.
177. The shroud of claim 175, wherein the interfacing structure
permits the elbow to rotate through 360.degree..
178. The shroud of claim 175, wherein the elbow comprises a first
end and a second end, and a swivel joint provided to the second end
that is adapted to be connected to an air delivery tube.
179. The shroud of claim 168, comprising an anti-asphyxia
valve.
180. The shroud of claim 179, wherein the anti-asphyxia valve is
provided to the elbow.
181. The shroud of claim 179, wherein the anti-asphyxia valve
comprises a clip portion that is configured to attach the valve to
the elbow.
182. The shroud of claim 179, wherein the anti-asphyxia valve
comprises a port and a flap portion to selectively close said
port.
183. The shroud of claim 182, wherein the flap portion and the clip
portion are co-molded with one another.
184. A cushion module for a mask system, comprising a cushion
constructed of a relatively soft elastomeric material to form a
seal with a patient's face in use, a frame constructed of a
relatively rigid material, said frame defining a breathing chamber,
wherein the cushion and frame are connected to each other, a
protruding vent arrangement having a plurality of holes, and a
frame opening configured to in-use allow a flow of breathable gas
into the breathing chamber for patient breathing, and wherein the
cushion module is structured to interact with a retaining portion
of a shroud to removably attach the cushion module and the shroud
together.
185. The cushion module of claim 184, wherein the cushion is
constructed to engage along a nasal bridge region, a cheek region,
and a lower lip/chin region of the patient's face when in use.
186. The cushion module of claim 184, wherein the breathing chamber
is constructed to receive a patient's nose.
187. The cushion module of claim 184, wherein the cushion comprises
silicone.
188. The cushion module of claim 187, wherein the cushion comprises
frosted silicone.
189. The cushion module of claim 184, wherein the connection of the
cushion and the frame to each other is an interlocking
relationship.
190. The cushion module of claim 184, wherein the cushion includes
one or more positioning features located around its circumference
to assist with alignment of the cushion with the frame.
191. The cushion module of claim 184, wherein the cushion includes
notches and/or protrusions to engage with complementary features in
the frame.
192. The cushion module of claim 184, wherein the connection of the
cushion to the frame is co-moulding.
193. The cushion module of claim 184, wherein the frame comprises
polycarbonate.
Description
CROSS-REFERENCE TO APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 13/745,077, now U.S. Pat. No. 8,528,561, filed on Jan. 18,
2013, which is a continuation of U.S. application Ser. No.
12/736,024, now U.S. Pat. No. 8,550,084, filed on Sep. 2, 2010,
which is the U.S. National Stage of PCT/AU2009/000241, filed Feb.
27, 2009, which claims benefit to U.S. Provisional Application Nos.
61/064,406, filed Mar. 4, 2008, 61/071,893, filed May 23, 2008, and
61/136,617, filed Sep. 19, 2008, each of which is incorporated
herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a mask system used for
treatment, e.g., of Sleep Disordered Breathing (SDB) with
Continuous Positive Airway Pressure (CPAP) or Non-Invasive Positive
Pressure Ventilation (NIPPV).
BACKGROUND OF THE INVENTION
[0003] Patient interfaces, such as a full-face or nasal mask
systems, for use with blowers and flow generators in the treatment
of sleep disordered breathing (SDB), typically include a soft
face-contacting portion, such as a cushion, and a rigid or
semi-rigid shell or frame. In use, the interface is held in a
sealing position by headgear so as to enable a supply of air at
positive pressure (e.g., 2-30 cm H.sub.2O) to be delivered to the
patient's airways.
[0004] One factor in the efficacy of therapy and compliance of
patients with therapy is the comfort and fit of the patient
interface.
[0005] The present invention provides alternative arrangements of
mask systems to enhance the efficacy of therapy and compliance of
patients with therapy.
SUMMARY OF THE INVENTION
[0006] One aspect of the invention relates to a mask system
provided without a forehead support adapted to engage the patient's
forehead.
[0007] Another aspect of the invention relates to a mask system
including a frame and a shroud removably connected to the frame and
adapted to attach headgear.
[0008] Another aspect of the invention relates to a mask system
including a frame defining a breathing chamber, a cushion provided
to the frame and adapted to form a seal with the patient's face,
and a shroud provided to the frame. The shroud and the frame are
co-molded with one another. The frame is constructed of a first,
relatively soft, elastomeric material and the shroud is constructed
of a second material that is more rigid than the frame. At least a
portion of the frame includes a concertina section having a
plurality of folds. Each of the folds has a side wall with the side
walls of the folds becoming progressively longer away from the
patient's face.
[0009] Another aspect of the invention relates to a cushion module
including a frame defining a breathing chamber and a cushion
adapted to form a seal with the patient's face. The frame and the
cushion are co-molded with one another. The cushion is constructed
of a first, relatively soft, elastomeric material and the frame is
constructed of a second material that is more rigid than the
cushion. At least a portion of the frame includes a concertina
section.
[0010] Another aspect of the invention relates to a method for
constructing a cushion module. The method includes molding a first
part of the cushion module with a first, relatively soft,
elastomeric material, co-molding a second part of the cushion
module to the first part with a second material that is more rigid
than the first material, and molding at least a portion of the
second part to include a concertina section.
[0011] Another aspect of the invention relates to a shroud for a
mask system including a retaining portion structured to retain a
frame, a pair of upper headgear connectors each including an
elongated arm and a slot at the free end of the arm adapted to
receive a headgear strap, and a pair of lower headgear connectors
each adapted to attach to a headgear strap, wherein the retaining
portion, the upper headgear connectors, and the lower headgear
connectors are integrally formed as a one piece structure.
[0012] Another aspect of the invention relates to a mask system
including a frame defining a breathing chamber, a cushion provided
to the frame and adapted to form a seal with the patient's face, a
shroud provided to the frame and adapted to attach headgear, and an
elbow provided to the frame and adapted to be connected to an air
delivery tube that delivers breathable gas to the patient. The
shroud includes a retaining mechanism structured to establish a
positive connection between the shroud and the frame.
[0013] Another aspect of the invention relates to a mask system
including a frame defining a breathing chamber and a cushion
provided to the frame. The cushion is adapted to engage at least a
portion of the patient's face. The cushion includes a base wall
connected to an undercushion layer and a membrane, wherein the
membrane extends around the perimeter of the cushion and contacts
the patient's face. The undercushion layer is positioned underneath
the membrane and supports the membrane. The under cushion layer
provides differential support to the membrane at predetermined
regions of the face.
[0014] Another aspect of the invention relates to a mask assembly
for use in medical applications having a top and bottom ends
defined by its position relative to a patient's face, wherein the
mask assembly is connected to a plurality of flexible straps, which
are adapted to engage the patient's head. The flexible straps
engage at least two elongated rigid arms integrally molded to a
portion of the mask assembly, and wherein the elongated arms are
molded to the mask assembly proximal to the top end of the mask
assembly.
[0015] Another aspect of the invention relates to a mask assembly
for use in medical applications including a main body connected to
a cushion adapted to cover nose and/or mouth and wherein the mask
assembly is attached by a force substantially perpendicular towards
the face and wherein the force is approximately constant along the
length of the mask and is balanced by a portion of the cushion
engaging the patient's cheeks.
[0016] Another aspect of the invention relates to a cushion for use
with a medical mask including an outer membrane layer adapted to
sealably engage a face and an undercushion layer adapted to support
the membrane layer. The membrane or undercushion layer includes a
surface positioned between the two layers adapted to allow the
layers to slide against the respective surface.
[0017] Another aspect of the invention relates to a mask system
including a frame defining a breathing chamber, a cushion provided
to the frame and adapted to form a seal with the patient's face,
and a releasable shroud adapted to engage a portion of the outer
surface of the frame, wherein the shroud is connected to straps to
position the mask system.
[0018] Another aspect of the invention relates to a mask assembly
for use in medical applications including an upper end and a lower
end wherein the upper end is adapted to cover the nose and the
lower end is adapted to cover the mouth of a patient. The mask
assembly includes no forehead support and includes two stiffened
members attached to the upper end on opposed sides of the mask
assembly, and wherein the stiffened members include a general
curved shape and adapted to avoid covering the patient's field of
vision.
[0019] Another aspect of the invention relates to a cushion for
attaching to a medical mask, wherein the cushion is flexible and
includes a membrane attached to the circumference of the cushion
adapted to seal against the face of a patient, and at least one
undercushion adapted to support the membrane and positioned
underneath the membrane to prevent collapse of the membrane, in
use. The membrane is softer than the undercushion. The undercushion
in the regions of nasal bridge or chin is between 0 mm and 30 mm in
height as measured between the base and the tip of the
undercushion.
[0020] Another aspect of the invention relates to a mask assembly
for use in medical applications including an upper end and a lower
end wherein the upper end is adapted to cover the nose and the
lower end is adapted to cover the mouth of a patient. The mask
assembly includes no forehead support and includes two stiffened
members attached to the upper end on opposed sides of the mask
assembly, and wherein the stiffened members include a general
curved shape and adapted to avoid covering the patient's field of
vision.
[0021] In an alternative embodiment, the mask system may include a
headgear connector or rigidizer structured to attach to the frame
with a snap-fit, mechanical interlock, friction fit, and/or grommet
arrangement (e.g., constructed of rubber).
[0022] In an alternative embodiment, the mask system may include
headgear having an arrangement of straps constructed of silicone
and/or Breath-O-Prene.TM. material.
[0023] Other aspects, features, and advantages of this invention
will become apparent from the following detailed description when
taken in conjunction with the accompanying drawings, which are a
part of this disclosure and which illustrate, by way of example,
principles of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings facilitate an understanding of the
various embodiments of this invention. In such drawings:
[0025] FIG. 1 is a front perspective view of a mask system
according to an embodiment of the present invention;
[0026] FIG. 1B is a perspective view showing the mask system of
FIG. 1 with headgear positioned on a patient's head;
[0027] FIG. 1C is a cross-sectional view through the mask system of
FIG. 1;
[0028] FIG. 1D is another cross-sectional view through the mask
system of FIG. 1;
[0029] FIG. 1E is a side view of the mask system of FIG. 1;
[0030] FIG. 2 is a front perspective view showing the frame and
cushion of the mask system of FIG. 1;
[0031] FIG. 3 is an exploded perspective view of the mask system of
FIG. 1 showing the frame, cushion, shroud, and elbow;
[0032] FIG. 4 is another exploded perspective view of the mask
system of FIG. 1 showing the frame, cushion, and shroud;
[0033] FIG. 5 is an exploded perspective view of the mask system of
FIG. 1 showing the shroud and assembled frame/cushion;
[0034] FIG. 6 is a front perspective view showing the shroud of the
mask system of FIG. 1;
[0035] FIG. 7 is a front perspective view showing the cushion of
the mask system of FIG. 1;
[0036] FIG. 8 is a cross-sectional view showing a portion of the
cushion of FIG. 7;
[0037] FIG. 8B is a cross-sectional view through nasal bridge and
chin regions of the cushion of FIG. 7;
[0038] FIG. 9 is a plan view of headgear laid out flat according to
an embodiment of the present invention;
[0039] FIG. 10 is a front perspective view of a mask system
according to another embodiment of the present invention;
[0040] FIG. 11 is a front perspective view showing the frame of the
mask system of FIG. 10;
[0041] FIG. 12 is a front view showing the frame of the mask system
of FIG. 10;
[0042] FIG. 13 is a side view showing the frame of the mask system
of FIG. 10;
[0043] FIG. 14 is a front perspective view showing the shroud of
the mask system of FIG. 10;
[0044] FIG. 15 is a front view showing the shroud of the mask
system of FIG. 10;
[0045] FIG. 16 is a side view showing the shroud of the mask system
of FIG. 10;
[0046] FIG. 17 is a rear perspective view showing the shroud of the
mask system of FIG. 10;
[0047] FIGS. 18-1 to 18-2 are cross-sectional views showing in
sequential relation attachment of the shroud to the frame of the
mask system of FIG. 10;
[0048] FIGS. 19-1 to 19-4 are cross-sectional views showing in
sequential relation attachment of the shroud to the frame of the
mask system of FIG. 10;
[0049] FIG. 20 is a perspective view showing an alternative
arrangement for attaching the shroud to the frame;
[0050] FIG. 21 is a rear perspective view showing the shroud of the
mask system of FIG. 10;
[0051] FIG. 22 is a cross-sectional view showing attachment of the
shroud to the frame of the mask system of FIG. 10;
[0052] FIG. 23 is a cross-sectional view showing attachment of the
shroud, frame, and elbow of the mask system of FIG. 10;
[0053] FIG. 24 is a cross-sectional view showing an alternative
arrangement for attaching the shroud to the frame;
[0054] FIG. 25 is a front perspective view of a mask system
according to another embodiment of the present invention;
[0055] FIG. 26 is a rear perspective view of the mask system of
FIG. 25;
[0056] FIG. 27 is a front perspective view of a mask system
according to another embodiment of the present invention;
[0057] FIG. 28 is an exploded view of the mask system shown in FIG.
27;
[0058] FIG. 29 is an enlarged front perspective view of the mask
system shown in FIG. 17;
[0059] FIG. 30 is a side view of the mask system shown in FIG.
27;
[0060] FIGS. 31-1 is a rear view of a cushion according to an
embodiment of the present invention;
[0061] FIG. 31-2 is a front view of the cushion shown in FIG. 31-1
with a partial cut-away;
[0062] FIG. 31-3 is a cross-section view through line 31-3-31-3 in
FIG. 31-1;
[0063] FIG. 31-4 is a cross-section view through line 31-4-31-4 in
FIG. 31-1;
[0064] FIG. 31-5 is a cross-section view through line 31-5-31-5 in
FIG. 31-1;
[0065] FIGS. 32-1 to 32-3 illustrate top, front, and side views
respectively of a concertina section according to an embodiment of
the present invention;
[0066] FIG. 33 is a side view of a mask system according to a
variation of the present invention;
[0067] FIG. 34 illustrates a cushion including a concertina section
according to an embodiment of the present invention;
[0068] FIGS. 35-1 to 35-3 are front, side, and rear views of a mask
system according to another embodiment of the present
invention;
[0069] FIG. 36 is a perspective view of a shroud for a mask system
according to an embodiment of the present invention;
[0070] FIGS. 37-1 to 37-3 are perspective, front, and side views of
a mask system according to another embodiment of the present
invention;
[0071] FIGS. 38-1 to 38-5 are perspective, front, top, side, and
bottom views of a shroud of the mask system shown in FIGS. 37-1 to
37-3;
[0072] FIGS. 39-1 to 39-6 are perspective, front, side, bottom, and
top views of a mask system according to another embodiment of the
present invention;
[0073] FIGS. 40-1 and 40-2 are perspective and side views of a mask
system according to another embodiment of the present
invention;
[0074] FIG. 40-3 is a perspective view of the frame of the mask
system shown in FIGS. 40-1 and 40-2;
[0075] FIGS. 40-4 and 40-5 illustrate a retaining member of the
frame shown in FIG. 40-3;
[0076] FIGS. 40-6 and 40-7 illustrate a clip-on upper headgear
connector of the mask system shown in FIGS. 40-1 and 40-2;
[0077] FIGS. 41-1 and 41-2 are rear and front perspective views of
a mask system according to another embodiment of the present
invention;
[0078] FIGS. 41-3 and 41-4 are exploded views of the mask system
shown in FIGS. 41-1 and 41-2;
[0079] FIGS. 41-5 to 41-12 are various views of a clip-on upper
headgear connector of the mask system shown in FIGS. 41-1 and
41-2;
[0080] FIG. 42-1 is a rear perspective view of a mask system
according to another embodiment of the present invention;
[0081] FIG. 42-2 is an exploded view of the mask system shown in
FIG. 42-1;
[0082] FIGS. 42-3 to 42-7 are various views of a clip-on upper
headgear connector of the mask system shown in FIG. 42-1;
[0083] FIGS. 43-1 to 43-4 are perspective, side, front, and rear
views of a mask system according to another embodiment of the
present invention;
[0084] FIG. 44 illustrates a mask system according to another
embodiment of the present invention; and
[0085] FIG. 45 illustrates a mask system according to another
embodiment of the present invention.
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0086] The following description is provided in relation to several
embodiments or examples which may share common characteristics and
features. It is to be understood that one or more features of any
one embodiment or example may be combinable with one or more
features of the other embodiments or examples. In addition, any
single feature or combination of features in any of the embodiments
or examples may constitute additional embodiments or examples.
[0087] In this specification, the word "comprising" is to be
understood in its "open" sense, that is, in the sense of
"including", and thus not limited to its "closed" sense, that is
the sense of "consisting only of". A corresponding meaning is to be
attributed to the corresponding words "comprise", "comprised" and
"comprises" where they appear.
[0088] The term "air" will be taken to include breathable gases,
for example air with supplemental oxygen.
[0089] The term "shroud" will be taken to include components that
partially or fully cover a second component within the illustrated
embodiments. In an embodiment, the shroud may include the component
that partially covers or is mounted on the frame components of the
illustrated embodiments.
[0090] The term "positive connection" will be taken to include
connections between components of the illustrated embodiments
wherein connectors mounted on respective components are adapted to
engage each other respectively.
1. Mask System
[0091] Embodiments of the invention are directed towards a mask
system provided without a forehead support adapted to engage the
patient's forehead. Such arrangement provides the mask system with
a less obtrusive arrangement which does not significantly affect
the patient's field of view. Although the system is designed such
that a forehead support is not required, such a forehead support
can be added if desired.
[0092] As described in greater detail below, the mask system
includes a frame, a cushion provided to the frame and adapted to
form a seal with the patient's face, a shroud provided to the frame
and adapted to attach headgear, and an elbow provided to the frame
and adapted to be connected to an air delivery tube that delivers
breathable gas to the patient. Headgear may be removably attached
to the shroud to maintain the mask system in a desired adjusted
position on the patient's face. The mask system is intended for use
in positive pressure therapy for users with Obstructive Sleep Apnea
(OSA) or another respiratory disorder.
[0093] While each embodiment below is described as including a
full-face or oro-nasal interface type, each embodiment may be
adapted for use with other suitable interface types. That is, the
interface type is merely exemplary, and each embodiment may be
adapted to include other interface types, e.g., nasal interface,
nasal mask, nasal prongs, etc.
[0094] 2. Stabilizing Mechanisms
[0095] The stabilizing mechanisms (e.g., frame, shroud, headgear
with associated headgear vectors) of a mask system according to
embodiments of the invention are structured to accommodate the
elimination of a forehead support from a full-face type interface.
For example, a forehead support typically eliminates rotation of
the mask system in the sagittal and coronal planes, so the mask
system and headgear according to embodiments of the invention are
structured to take on these functions since there is no forehead
support.
[0096] The headgear is connected to the top and bottom of the frame
either directly or via the shroud, which shroud provides headgear
connection points for headgear positioned and arranged to stably
maintain the mask system in position on the patient's face.
[0097] 2.1 Frame
[0098] As shown in FIGS. 1, 1B-1E, and 2-5, the frame 1040 of the
mask system 1010 is structured to maintain the cushion 1060, shroud
1020, and elbow 1070 in an operative position with respect to the
patient's face. The frame 1040 is constructed (e.g., injection
molded) from a more rigid material (e.g., polyurethane) than the
cushion 1060 (made of, e.g., silicone), however other materials may
function likely as well (e.g., polycarbonate). In an embodiment,
the frame has a general wall thickness of about 1-2 mm, e.g., 1.5
mm.
[0099] The frame 1040 defines a breathing chamber or cavity adapted
to receive the patient's nose and mouth and provide air
communication to the patient. One or the lower portion of the frame
1040 includes an opening 1046 adapted to receive or otherwise
communicate with the elbow 1070 (e.g., swivel elbow) and another or
upper portion of the frame 1040 includes a vent arrangement 1076
for gas washout. In addition, the upper portion of the frame 1040
includes an interfacing structure 1048 adapted to interface or
otherwise removably connect to the shroud 1020.
[0100] FIGS. 27-30 shows a mask system 10 including a frame 40 with
a cushion 44 that provides a sealing portion or sealing ring
adapted to form a seal with the patient's nose and/or mouth. Also,
the frame 40 includes an opening 46 that is adapted to communicate
with the elbow 70.
[0101] 2.2 Shroud
[0102] As shown in FIGS. 1 and 3-6, the shroud 1020 is connected to
the frame 1040 and is structured to attach headgear to the mask
system. In an embodiment, the shroud 1020 is constructed (e.g.,
injection molded) of a resilient material including but not limited
to plastic or nylon (e.g., Nylon 12). However, the shroud may be
constructed of other suitable materials, e.g., polycarbonate,
polypropylene, thermoplastic elastomer (TPE), Pocan.RTM., etc. In
an embodiment, the shroud has a general wall thickness of about 1-2
mm, e.g., 1.3 mm.
[0103] The top end of the shroud 1020 is adapted to be positioned
proximal to the nasal bridge region or nose of the patient and the
bottom end is adapted to be positioned proximal to the mouth or
chin of the patient. The top end includes an opening or vent
receiving hole 1021 to accommodate the vent arrangement 1076 that
protrudes from the frame 1040, and the bottom end includes an
opening or elbow hole 1032 to accommodate the elbow 1070 and elbow
opening into the frame 1040 (e.g., shroud provides no contact with
elbow when assembled).
[0104] Upper headgear connectors 1024 extend from each side of the
top end, and lower headgear connectors 1025 extend from each side
of the lower end. The headgear connectors 1024, 1025 may be
integrally molded or otherwise attached to the shroud.
[0105] 2.2.1 Upper Headgear Connectors
[0106] Each upper headgear connector 1024 includes an elongated arm
1026 and a slot or receiving hole 1027 at the free end of the arm
1026 adapted to receive a respective headgear strap. In use, the
arms 1026 extend around the face of the patient in a generally
concave angle below the eyes of the patient so as to avoid the
patient's field of view, i.e., direct headgear away from the
patient's eyes. For example, as shown in FIG. 1E, each arm 1026 may
extend at an angle a between about 10-25.degree. (e.g., 17.degree.)
with respect to horizontal. That is, each arm 1026 is suitably
formed, shaped, or contoured to follow the contours of the
patient's face and avoid line of sight in use. In an embodiment,
the shape of the arms may be generally arcuate and adapted to
extend in a direction across the cheek of the patient, while
avoiding the eyes or limiting the field of vision. In an
embodiment, the arms may be integrally molded to the shroud of the
mask system. One possible advantage of molding the arms onto the
shroud is that it greatly increases manufacturability and also the
shroud may be easily replaced in the case of accidental breakage of
the arms rather than replacing the complete mask system.
Additionally, molding of the arms onto the shroud may greatly
increase the strength of the connection and reduce or limit the
actual likelihood of breakage of the arms.
[0107] In an embodiment, the arms 1026 are at least semi-rigid
(e.g., relatively rigid) so as to prevent up and down movement or
bending of the arms relative to the face of the patient. Thus, the
arms 1026 may act as rigidizers to effectively act as a level
arrangement and generate a mechanical advantage wherein the
pressure or force applied to top end of the mask system is
readjusted to a fulcrum point being about the center of balance
between the top and bottom ends of the mask system. In an
embodiment, the arms are attached to the highest possible point
relative to the mask system to additionally stabilize the
configuration. In an embodiment, the fulcrum point or moment of
pivoting is positioned between the upper and lower connection
points of the straps, and wherein the design, angle, length and/or
configuration of the arms 1026 may effectively adjust the fulcrum
point. In the illustrated embodiment, the fulcrum point is shown to
be between the vent arrangement and elbow of the mask system.
Additionally, when positioned on the face, the mask system may have
a fulcrum point around or about the region between the bottom of
the patient's nose and lip area. This feature effectively
stabilizes the mask system on the patient's face without the
traditional need for a forehead support.
[0108] The net result of the arms 1026 mounted in a position
extending from the top end of the mask system around the face of
the patient is that the mask system is more stable and reduces the
net torsional forces experiences about the x-axis 1001 (see FIG. 1)
for the mask system in use. Please note that the arms 1026 may be
rigidly connected to the mask system in other suitable positions to
generate a similar result.
[0109] In an embodiment, the arms 1026 may be used to stabilize the
mask system by contacting the patient's face at the cheeks. A cheek
pad may be provided to the inner surface of the arm to support the
arm on the patient's cheek in use. Also, the arms 1026 may be
enveloped in a soft fabric sleeve to act as additional padding
against the cheeks of the patient. The soft fabric sleeve may be in
the configuration of an elastic tube covering a portion of the arms
1026.
[0110] 2.2.2 Lower Headgear Connectors
[0111] Each lower headgear connector 1025 includes an abbreviated
arm and a clip receptacle 1031 at the free end of the arm adapted
to be removably interlocked with a headgear clip associated with a
respective headgear strap. The clips allow for easier positioning
or donning/removal of the mask system. In an embodiment, the
abbreviated arms and clips are also relatively rigid so as to
prevent lateral movement of the arms along the y-axis 1002,
relative to the mask system in use.
[0112] FIGS. 27-30 illustrate an exemplary headgear clip 33 adapted
to be removably interlocked with a clip receptacle 31. As best
shown in FIG. 28, each clip 33 includes two spring arms 35 adapted
to interlock with the respective clip receptacle 31 with a snap-fit
and a slot 37 adapted to receive a respective headgear strap in
use.
[0113] 2.2.3 Alternative Headgear Connectors
[0114] As shown in FIGS. 27-30, the arm 26 may be removably coupled
to the shroud, e.g., arm 26 includes clip structure adapted to
removably interlock with a clip receptacle provided to the shroud.
This arrangement allows different styles of upper and lower
headgear connectors to be used with the shroud, e.g., arms for both
upper and lower headgear connectors, clips for both upper and lower
headgear connectors, different length arms for upper and lower
headgear connectors, etc.
[0115] However, the shroud may provide other suitable arrangements
for attaching headgear straps of headgear. Also, the shroud may
include one or more additional components, e.g., forehead
support.
[0116] 2.2.4 Headgear Connector Positioning
[0117] In the embodiment of FIGS. 1-6, the upper and lower headgear
connectors 1024, 1025 provide headgear connection points that are
as far from each other as possible (i.e., top and bottom of frame)
to allow for greater adjustability (e.g., allows adjustment at the
top and bottom of the mask system) and stability (e.g., anchor
points spread out around the mask system so more secure on the
patient's face). Also, the upper headgear connectors are positioned
as close to the top of the mask system as possible without
obstructing the patient's eyes in use.
[0118] 2.2.5 Separate Shroud
[0119] In the embodiment of FIGS. 1-6, the shroud 1020 is formed
separately (e.g., molded) and attached to the frame 1040. Such
arrangement facilitates molding of the shroud, allows different
materials to be used for the frame and shroud (e.g., frame can be
semi-rigid or rigid for stability and shroud with headgear
rigidizers can be flexible for adjustment, allows the shroud to
hide elbow retention features around elbow/frame opening for
retaining elbow to frame (e.g., provides visual shroud for
aesthetics), allows frame to be free of lower clip receptacles,
allows shroud to be used with different size frames, and allows the
shroud to be designed or stylized to minimize obtrusiveness of the
mask system. The separate shroud may also allow the headgear,
frame, cushion, and/or elbow to be replaced or washed
independently.
[0120] 2.2.6 Sleeves
[0121] In an embodiment, soft fabric sleeves may be mounted on the
upper and/or lower headgear connectors. For example, the sleeves
may be elastic and adapted to slide over the arms of the headgear
connectors to form a tight fit. In an embodiment, the sleeves form
elastic tubes. The sleeves may be padded to increase the comfort of
the mask system in use. The sleeves may be particularly useful
where the arms of the headgear connectors contact the patient's
skin, e.g., to protect the patient's skin from irritation.
[0122] 2.2.7 Arm Extends Over the Patient's Ear
[0123] FIGS. 35-1 to 35-3 and 36 illustrate a shroud 220 for mask
system 210 according to another embodiment of the present
invention. The shroud 220 includes an annular retaining portion 222
structured to retain the frame 240 and upper and lower headgear
connectors 224, 225 on each side of the retaining portion 222. In
the illustrated embodiment, the shroud 220 is integrally formed in
one piece (e.g., see FIG. 36).
[0124] In the illustrated embodiment, each upper headgear connector
224 includes an elongated arm 226 and a slot 227 at the free end of
the arm 226 adapted to receive a respective rear strap 298 in use.
As illustrated, the arm 226 is suitably contoured to extend along
the cheeks and over the patient's ear just anterior of the
patient's temple and retain the respective rear strap 298 in spaced
relation over the patient's ear, e.g., to avoid the strap rubbing
or irritating the patient's ear in use.
[0125] Also, each arm 226 is structured to extend along and engage
an upper strap 292 of the headgear in use. As illustrated, each arm
226 is secured to the upper strap 292 to add rigidity to the strap
and stabilize the mask system on the patient's face in use. In
addition, the strap 292 provides padding to the arm 226 on the
patient's face in use. In an embodiment, the upper strap 292 may be
fixed to the arm 226 by gluing or stitching for example.
Alternatively, the arms 226 may be encapsulated by or inserted into
respective straps 292 so that the arms 226 are substantially not
visible.
[0126] Each lower headgear connector 225 includes an abbreviated
arm 228 with a slot 229 at the free end of the arm 229 adapted to
receive a respective lower strap 294 in use. As illustrated, the
arm 228 is suitably oriented to retain the respective lower strap
294 in spaced relation under the patient's ear, e.g., to avoid the
strap rubbing or irritating the patient's ear in use.
[0127] In an embodiment, each arm may be attached to the upper end
of the mask system and curves below the patient's field of vision
or eyes and curves upwards at an angle between about 10 to 20
degrees away from the horizontal axis.
[0128] In an alternative embodiment, as shown in FIG. 36, each
lower headgear connector 225 may include a clip receptacle 231
adapted to be removably interlocked with a headgear clip (not
shown) associated with a respective lower strap 294. In an
embodiment, the headgear clip receptacle and clip may be similar to
that on ResMed's Mirage Liberty.TM. mask. Exemplary clip
arrangements are disclosed in U.S. Patent Publication Nos.
2007/0144525 and 2006/0283461, each of which is incorporated herein
by reference in its entirety.
[0129] 2.2.8 Shroud Without Upper Headgear Connector
[0130] FIGS. 37-1 to 37-3 illustrate a mask system 310 according to
another embodiment of the present invention. As illustrated, the
mask system 310 includes a shroud 320, a frame 340, a cushion 344,
and an elbow 370.
[0131] As best shown in FIGS. 38-1 to 38-5, the shroud 320 includes
an opening 322 structured to receive the elbow 370 and a headgear
connector 325 on each side thereof In the illustrated embodiment,
each headgear connector 325 includes a clip receptacle 331 adapted
to be removably interlocked with a headgear clip (not shown)
associated with a respective lower headgear strap.
[0132] The frame 340 is removably attached to the shroud 320, e.g.,
fingers and tabs 345 extending from opening 322 adapted to engage
collar of frame 340.
[0133] The frame 340 includes an upper headgear connector 324 on
each upper side thereof. Each headgear connector 324 includes a
clip retainer 333 adapted to be removably interlocked with a
headgear clip (not shown) associated with a respective upper
headgear strap.
[0134] FIGS. 39-1 to 39-6 illustrate an alternative version of the
mask system 310, which is indicated with similar reference
numerals. As illustrated, the frame 340 is provided without upper
headgear connectors, and the each clip receptacle 331 includes an
alternative configuration (e.g., holes for snap-fit tabs on the
clip). Also, the shroud 320 in FIGS. 39-1 to 39-6 includes support
bars 329 structured to wrap around respective auxiliary ports 343,
while the shroud 320 in FIGS. 37-1 to 38-5 includes support bars
329 that extend in front of respective auxiliary ports 343.
[0135] 2.3 Headgear
[0136] Headgear may be removably attached to the headgear
connectors 1024, 1025 of the shroud 1020 to maintain the mask
system 1010 in a desired position on the patient's face, e.g., see
FIG. 1B.
[0137] As shown in FIG. 9, the headgear 1090 includes a pair of
upper and lower straps 1092, 1094 with the upper straps 1092
removably attached to respective upper headgear connectors 1024 and
the lower straps 1094 removably attached to respective lower
headgear connectors 1025. The free end of each strap may include a
Velcro.RTM. tab structured to engage the remainder of the strap to
secure the strap in place. Such Velcro.RTM. attachment also allows
adjustment of the length of the straps. However, the upper and
lower headgear straps may be secured to the shroud in any other
suitable manners, e.g., adjustable ladder-lock arrangement,
etc.
[0138] The upper straps 1092 split at the crown of the patient's
head to top straps 1096 (e.g., connected to one another by a
buckle) adapted to pass over the top of the patient's head in use
and rear straps 1098 adapted to pass behind the patient's head in
use. In an embodiment, the headgear 1090 is structured to be
self-supporting.
[0139] In FIG. 9, the top straps 1096 are adapted to be connected
to one another by a buckle. In an alternative embodiment, as shown
in FIG. 27-30, headgear 90 may include upper and lower straps 92,
94, top strap 96, and rear strap 98, with the top straps 96
integral with one another.
[0140] The upper straps 1092 are designed to adjust the position of
the mask in a similar way that an adjustable forehead support would
alter the position of the mask system, i.e., move the top of the
mask system closer or further away from the patient's nasal
bridge.
[0141] Without the forehead support, the headgear is connected at
the top and bottom of the mask frame 1040 via the shroud 1020, and
in order to avoid the eyes and ears, the arm 1026 of the upper
headgear connector extends at an angle. In doing so, the headgear
vectors V1 and V2 (see FIGS. 1 and 1B) are aligned such that the
mask system may have a tendency to ride up the patient's face
(i.e., upper headgear connectors position upper headgear vectors
upwardly from horizontal and lower headgear connectors position
lower headgear vectors generally horizontal). By splitting the
upper headgear strap 1092 at the crown of the patient's head (i.e.,
top and rear straps 1096, 1098), the upper headgear vectors are
realigned to prevent the mask system from sliding up the patient's
face.
[0142] 2.3.1 Headgear Adjustment
[0143] FIGS. 35-1 to 35-3 illustrate headgear 290 attached to the
headgear connectors 224, 225 of the shroud 220 to maintain the mask
system in a desired position on the patient's face.
[0144] In the illustrated embodiment, the headgear 290 includes a
pair of upper or top straps 292, a pair of lower or bottom straps
294, and a pair of rear straps 298. In use, the upper straps 292
are secured to respective upper connectors or arms 226, the lower
straps 294 are removably attached to respective lower connectors
via slots 229/clip arrangement 231, and the rear straps 298 are
removably attached to respective upper connectors via slots 227.
The upper straps 292 may include upper strap portions adapted to
pass over the top of the patient's head and couple to one another,
e.g., via a headgear buckle or adjustable ladder-lock arrangement
299. In the illustrated embodiment, the lower straps 294 and rear
straps 298 are formed in one piece.
[0145] This headgear arrangement allows adjustment to occur at
three positions, i.e., upper straps 292 at the headgear buckle 299,
lower straps 294 at the slot 229/clip 231 connection, and rear
straps 298 at the slot 227 connection.
[0146] As illustrated, the free end of each strap may include a
hook and loop tab 295 (e.g., Velcro.RTM.) structured to engage the
remainder of the strap to removably secure the strap in place. Such
hook and loop attachment also facilitates adjustment of the length
of the straps.
[0147] In the illustrated embodiment, the lower straps 294 and rear
straps 298 are adapted to join and pass behind the patient's head
in use (e.g., see FIG. 35-3). As illustrated, the lower straps 294
join at an angle a (e.g., similar to the bottom strap in ResMed's
Mirage Liberty mask) to prevent the strap from irritating the
patient's neck and/or prevent movement of the strap due to movement
of the patient's neck in use.
[0148] In an embodiment, the headgear may be similar to that for
ResMed's Mirage Liberty mask, however the top straps have been
modified and there is an added rigidizer system. The top straps may
be similar to ResMed's Swift style headgear, with the rigidizers
extending along the sides.
[0149] 2.3.2 Alternative Headgear Material
[0150] FIGS. 43-1 to 43-4 illustrate a mask system 610 including a
mask 615 and headgear 690 according to another embodiment of the
present invention. In the illustrated embodiment, the headgear 690
includes an arrangement of straps wherein some of the straps are
constructed of silicone and some of the straps are constructed of
Breath-O-Prene.TM. material. However, the headgear may be
constructed such that the straps are completely constructed of
silicone or completely constructed of Breath-O-Prene.TM.
[0151] As illustrated, the lower strap portion 692 of the headgear
is constructed of Breath-O-Prene.TM. and extends along the cheeks
and around the back of the patient's head. The upper strap portion
694 of the headgear is constructed of silicone and includes side
straps 694(1) that extend along the upper cheek and over the
patient's ear, a top strap 694(2) that extends over the top of the
patient's head, rear straps 694(3) that extend behind the patient's
head and connects to the lower strap portion 692 (see FIG. 43-4),
and connecting portions 694(4) that extend from respective side
straps 694(1) in front of the patient's ear and connect to the
lower strap portion 692.
[0152] The headgear straps may be connected to the mask in any
suitable manner For example, in the illustrated embodiment, the
lower strap portion 692 is connected to the mask by a headgear clip
arrangement and the upper strap portion 694 is connected to the
mask using an elongated buckle 695 with buckle portions on each end
thereof.
[0153] In an embodiment, the headgear straps are arranged such that
the force vectors applied by the headgear to the mask are
substantially perpendicular to the mask and substantially parallel
to one another (e.g., as shown by the arrows in FIG. 43-2). This
arrangement enhances the mask seal as the headgear forces the mask
directly into the patient's face.
[0154] 3. Seal
[0155] The seal (i.e., cushion) of the mask system is structured to
accommodate the elimination of a forehead support from a full-face
type interface.
[0156] 3.1 Cushion
[0157] As shown in FIGS. 1-5 and 7-8, the cushion 1060 is
structured to interface with the frame 1040 and form a seal with
the patient's nose and mouth in use. In the illustrated embodiment,
the cushion is a full-face cushion adapted to engage the patient's
face generally along nasal bridge, cheek, and lower lip/chin
regions of the patient's face. However, other cushion interfaces
are possible, e.g., nasal.
[0158] The cushion 1060 is structured be more compliant or flexible
(e.g., particularly in the nasal bridge region) to accommodate more
movement due to loss of some stability without a forehead
support.
[0159] The cushion 1060 is constructed of a soft and flexible
biocompatible material, e.g., such as silicone. In the illustrated
embodiment, the cushion 1060 includes a dual wall configuration
wherein the cushion comprises an undercushion or support wall 1062
underneath a membrane 1064 as shown in FIG. 8.
[0160] The membrane 1064 is generally softer and less stiff than
the undercushion 1062 and provides a seal against the patient's
face in use. The membrane may be relatively thin to allow for wider
fit range and better conformance to the patient's face in view of
less mask stability with a forehead support. The undercushion is
structured to generally support the membrane and prevents collapse
of the membrane when the mask system is attached and tightened
using the headgear.
[0161] The membrane 1064 is generally concave and curves inwards
towards the breathing chamber. The undercushion 1062 may also curve
inwardly but is generally shorter, thicker, and more rigid than the
membrane.
[0162] In an embodiment, the undercushion 1062 at the regions of
the nasal bridge and/or chin of the patient is shorter in height or
completely absent and the height from the tip to base of the
undercushion 1062 may be between about 0 mm and 30 mm. The membrane
is generally longer than the undercushion 1062 at any given
cross-section and may be between about 1 mm and 40 mm. For example,
FIG. 8B illustrates a cross-section through nasal bridge and chin
regions of the cushion to illustrate the membrane 1064 without an
undercushion in these regions.
[0163] In an embodiment, the undercushion 1062 may only be provided
in selected regions of the mask system, e.g., where the mask system
is to be pushed away from the patient's face. Certain
pre-determined regions of the patient's face may be preferably
avoided for applying pressure by the tightening of the headgear. In
the illustrated embodiment, the nasal bridge and chin regions of
the patient do not include an undercushion 1062. In these regions,
the undercushion is only provided along lateral sides of the
cushion (e.g., see FIG. 7) which press against the cheeks of a
patient so as to more evenly distribute the force vectors applied
by the mask system in use. In an embodiment, the undercushion may
be relatively stiff along the cheek regions because these points of
contact are acting as anchor points, i.e., holds mask system in
position to provide effective seal.
[0164] This configuration of avoiding the nasal bridge and chin of
the patient may increase the comfort of the mask system for
patients by reducing the pressure or force applied to sensitive
areas or to protruding regions of the patient's face that
experience relatively higher contact pressures. Additionally, this
arrangement avoids the cushion pinching the nasal bridge of the
patient when the mask system is adjusted. Additionally, the cushion
of this embodiment may be noticeably softer in the regions of the
nasal bridge and chin because of the absence of the
undercushion.
[0165] In an embodiment, the undercushion may include a variable
height, stiffness, and/or thickness to generate a variable softness
in the aforementioned predetermined regions of the face that
require lighter support.
[0166] In the illustrated embodiment, the cushion may be structured
to seal lower down on the patient's nasal bridge and the eye
sockets so that the cushion is less obtrusive.
[0167] In an embodiment, the cushion may be generally frosted
except at patient contacting surfaces where it is polished. In an
embodiment, the frosting of the cushion may reduce restriction
between the face and membrane and/or the membrane and undercushion.
The frosting allows the surface of the membrane and undercushion to
slide against each other's respective surface without the same
restriction of unfrosted silicone. This feature may also prevent or
limit sticking of the membrane to the undercushion components and
also may generally improve the overall comfort and sealing
properties of the cushion. Additionally, the frosting of the
cushion may be easier to manufacture and may lead to a reduction of
costs of manufacturing. The cushion may be constructed of frosted
silicone or other suitable materials.
[0168] 3.2 Cushion Lower On Nasal Bridge
[0169] FIGS. 31-1 to 31-5 illustrate various views of a cushion 44
(e.g., constructed of silicone) according to an embodiment of the
present invention. As illustrated, the cushion 44 includes a base
wall 44(1) provided to the frame, an undercushion layer (UCL) 44(2)
extending away from the base wall 44(1), and a membrane 44(3)
provided to substantially cover the UCL 44(2) and provide a sealing
structure. In the illustrated embodiment, the cushion 44 is
structured to sit lower on the nasal bridge to reduce mask
obtrusiveness and improve "line of sight" in use.
[0170] Also, as best shown in FIGS. 31-3 and 31-5, the UCL 44(2)
design in the nasal bridge region is structured to provide improved
stability across the nasal bridge in use. As shown in FIGS. 31-1
and 31-3, the UCL is not provided in the lower lip/chin region.
However, other arrangements of the UCL are possible, e.g., UCL
around entire perimeter.
[0171] In an embodiment of the cushion shown in FIGS. 31-1 to 31-5,
D1 may be about 15-20 mm, e.g., 18.2 mm, D2 may be about 53-59 mm,
e.g., 55.8 mm, D3 may be about 88-93 mm, e.g., 90 mm, D4 may be
about 78-83 mm, e.g., 81.1, D5 may be about 58-63 mm, e.g., 60 mm,
D6 may be about 95-100 mm, e.g., 98.1 mm, D7 may be about 57-62 mm,
e.g., 59.7 mm, D8 may be about 77-82 mm, e.g., 79 mm, D9 may be
about 88-93 mm, e.g., 90.7 mm, D10 may be about 30-35 mm, e.g.,
33.1 mm, D11 may be about 14-19 mm, e.g., 16.4 mm, D12 may be about
8-13 mm, e.g., 9.6 mm, D13 may be about 0.3-0.5 mm, e.g., 0.35 mm,
D14 may be about 0.4-0.6 mm, e.g., 0.5 mm, and D15 may be about
0.3-0.5 mm, e.g., 0.4 mm. Although specific dimensions and ranges
are indicated, it is to be understood that these dimensions and
ranges are merely exemplary and other dimensions and ranges are
possible depending on application. For example, the exemplary
dimensions may vary by 10-20% or more or less depending on
application.
[0172] 3.3 Cushion Higher On Nasal Bridge
[0173] FIGS. 35-1 and 35-2 illustrate a full-face cushion 244
adapted to engage the patient's face generally along nasal bridge,
cheek, and lower lip/chin regions of the patient's face. In this
embodiment, the cushion 244 is structured such that it is
positioned higher on the bridge of the nose for sealing and comfort
(e.g., with respect to the cushion 44 described above). The cushion
244 may also be better for anthropometrics, i.e., the cushion will
fit more people.
[0174] In an embodiment, the cushion 244 may include a concertina
section as described below (e.g., in the nasal bridge region) to
enhance the flexibility of the cushion in use.
[0175] 3.4 Concertina Section
[0176] As best shown in FIGS. 30 and 33, a concertina section 50
may be provided in a nasal bridge region of the cushion and/or
frame. As illustrated, the concertina section 50 includes a bellows
structure with one or more folds 52 that provide a higher degree of
flexibility or increased movement. That is, the concertina section
50 provides a higher level of adaptability or flexibility to the
nasal bridge region of the cushion/frame which is a more sensitive
region of the patient's face in use. Moreover, the concertina
section 50 provides increased movement without compromising
seal.
[0177] FIGS. 32-1 to 32-3 illustrate various views of a concertina
section 50 (isolated from the remainder of the cushion/frame) with
one or more folds 52 according to an embodiment of the present
invention. As best shown in FIG. 32-3, the folds may have different
lengths, depths, and/or contours with respect to one another to
optimize the concertina effect, e.g., provide sufficient degree of
movement without compromising seal. For example, as shown in FIG.
32-3, each fold 52 includes a first side wall 52(1) and a second
side wall 52(2) that interconnects adjacent side walls 52(1).
[0178] In the illustrated embodiment, the first side walls 52(1)
and/or the second side walls 52(2) may become progressively longer
away from the patient's face. For example, the first side wall
52(1) and/or the second side wall 52(2) adjacent patient's face, or
the combination of side walls 52(1) and 52(2), may have a length
that is longer than and in some cases significantly longer than the
adjacent side wall 52(1) and/or 52(2) (e.g., one side wall at least
25% greater than and up to 5.times. as long as the other side wall,
e.g., 1.times., 2.times., 3.times., or 4.times.).
[0179] The folds may be constructed and arranged to provide a
predetermined order of movement or folding, e.g., folds structured
to fold in a sequential or progressive manner wherein one fold
collapses before an adjacent fold collapses. For example, upon
application of force, the folds closest to the patient's face may
fold or collapse before the folds furthest from the patient's face.
Also, the folds may be constructed and arranged to provide various
degrees of fold or collapse, e.g., folds may fold or collapse more
than others.
[0180] In an embodiment of the concertina section shown in FIGS.
32-1 to 32-3, D1 may be about 50-60 mm, e.g., 55.7 mm, D2 may be
about 5-15 mm, e.g., 9.7 mm, and D3 may be about 0.3-0.5 mm, e.g.,
0.4 mm. Although specific dimensions and ranges are indicated, it
is to be understood that these dimensions and ranges are merely
exemplary and other dimensions and ranges are possible depending on
application. For example, the exemplary dimensions may vary by
10-20% or more or less depending on application.
[0181] It should be appreciated that a concertina section 50 may be
provided in other regions of the cushion and/or frame, e.g.,
depending on patient comfort. For example, the concertina section
50 may be provided around the entire perimeter of the cushion
and/or frame or may be provided in selected regions of the cushion
and/or frame.
[0182] Also, the flexibility of the concertina section 50 may be
varied and may be varied in different regions of the cushion and/or
frame, e.g., depending on patient comfort. For example, the cushion
and/or frame may include a concertina section in the nasal bridge
region with a relatively high degree of flexibility and a
concertina section in the lower lip/chin region with a relatively
low degree of flexibility. The flexibility of the concertina
section 50 may be varied by varying the number of folds 52 (e.g.,
1-5 folds), the wall lengths, the wall thickness of the folds 52,
the depth of the folds 52, etc.
[0183] As noted above, the cushion and frame may be co-molded of
two parts with different materials/rigidities or may be integrally
formed of the same material. In both embodiments, the concertina
section may be provided in the frame and/or the cushion.
[0184] In FIGS. 27-30, the cushion 44 and frame 40 are co-molded of
two parts with the concertina section 50 provided in the frame 40.
The frame 40 and cushion 44 include different rigidities in order
to optimize the function of each part. For example, one part (i.e.,
cushion 44) may be constructed of a relatively soft, supple
material to optimize the sealing effect and the other part (i.e.,
frame 40) may be constructed of a more rigid material to provide
adequate support for the cushion while at the same time allowing a
sufficient degree of movement to optimize the concertina effect.
While the frame is more rigid than the cushion, the frame may be
constructed of a flexible material to allow the concertina
effect.
[0185] In FIG. 33, the frame 40 and cushion 44 are integrally
formed in one piece with the concertina section 50 provided in the
frame 40. The material properties and/or dimensions may be
selectively modified to optimize sealing and concertina
effects.
[0186] For both embodiments of FIGS. 27-30 and 33, it should be
appreciated that the concertina section may be alternatively
provided in the cushion 44 or in both the frame 40 and cushion 44.
For example, FIG. 34 illustrates a concertina section 50 integrally
formed with the cushion 44 in the nasal bridge region.
[0187] 4. Elbow
[0188] As shown in FIG. 3, the elbow 1070 (e.g., constructed of a
relatively hard material such as polycarbonate or polypropylene)
includes a first end portion 1074(1) and a second end portion
1074(2). The first end portion 1074(1) provides an interfacing
structure structured to interface or otherwise attach to the frame
1040. The second end portion 1074(2) is adapted to be connected to
an air delivery tube.
[0189] 4.1 Elbow Connection to Frame
[0190] The frame 1040 is structured to maintain the elbow 1070 in
an operative position with respect to the patient's face. That is,
the frame acts as a carrier and bearing surface for the elbow. The
frame and elbow may connect with a friction fit, snap-fit,
mechanical interlock, or other suitable attachment mechanism.
However, other suitable arrangements for attaching the elbow to the
frame are possible.
[0191] In the illustrated embodiment, the elbow 1070 includes a
series of tangs 1075 adapted to releasably engage within the
opening 1032 of the frame 1040, e.g., with a snap-fit. The tangs
1075 hold the elbow in place (e.g., preferably a relatively
airtight connection) and permit rotation or swiveling of the elbow
with respect to the frame.
[0192] That is, the elbow is rotatably attached to the frame so
that the elbow may be rotated relative to the frame in use, e.g.,
360.degree. rotation. This arrangement allows the elbow to assume
different orientations in use, e.g., depending on patient
preference. For example, the elbow may assume a first orientation
so that the elbow extends generally downwardly from the mask to
direct the air delivery tube under the patient's head in use.
Alternatively, the elbow may be rotated and assume a second
orientation so that the elbow extends upwardly from the mask to
direct the air delivery tube over the patient's head in use. In an
embodiment, the frame and elbow may be constructed of dissimilar
materials to prevent or at least reduce squeak between the
components in use.
[0193] The second end portion of the elbow may be provided to a
swivel joint adapted to be connected to the air delivery tube. For
example, FIGS. 27-30 illustrate a swivel joint 80 provided to the
second end portion 74(2) of elbow 70. In the illustrated
embodiment, the swivel joint 80 is provided to a short tube 82
(e.g., extendable and retractable tube) that interconnects the
elbow with the air delivery tube. In an embodiment, the swivel
joint 80 may be integrally formed in one piece with the short tube
82.
[0194] 4.2 AAV
[0195] The elbow 1070 includes a slot 1081 to receive an
anti-asphyxia valve (AAV), a port 1079 that is selectively closed
by a flap portion of the AAV (depending on the presence of
pressurized gas), and structure for attaching the AAV, e.g., with a
snap-fit.
[0196] FIGS. 27-30 illustrate an exemplary AAV 85 including a flap
portion 86 to selectively close port 79 in elbow 70. In this
embodiment, a clip portion 88 is provided to the flap portion 86
for attaching the AAV 85 to the elbow 70. In the illustrated
embodiment, the flap portion 86 and the clip portion 88 are
co-molded with one another to form a one-piece, integrated
component. However, the flap portion 86 and clip portion 88 may be
secured to one another in other suitable manners, e.g., mechanical
interlock.
[0197] In an embodiment, the flap portion 86 may be constructed of
a relatively soft elastomeric material (e.g., silicone) and the
clip portion 88 may be constructed of a more rigid material (e.g.,
rigid plastic) for interfacing with the elbow 70.
[0198] The clip portion 88 of the AAV 85 includes structure for
removably interlocking with the elbow 70, e.g., with a snap-fit.
For example, the clip portion 88 may include tabs structured to
interlock with respective recesses/protrusions provided to the
elbow.
[0199] FIGS. 35-1 and 35-2 illustrate an elbow 270 including a port
279 that is selectively closed by a flap portion 286 of the AAV 285
(depending on the presence of pressurized gas). Also, FIGS. 37-1 to
37-3 illustrate elbow 370 including a port 379 and a slot 381 to
retain the AAV.
[0200] Alternative embodiments of the AAV are disclosed in PCT
Application No. PCT/AU2006/000031, which is incorporated herein by
reference in its entirety.
[0201] 4.3 Large Diameter End Portion
[0202] As shown in FIGS. 27-30, the first end portion 74(1) of the
elbow 70 may provide a relatively large diameter which allows the
potential for cleaner/smoother lines thereby contributing to the
overall mask aesthetic and reduced obtrusiveness. In addition, the
relatively large diameter elbow offers the potential for the
patient's nose to protrude into the elbow cavity thereby permitting
the mask to be brought closer to the patient's face (i.e., reduced
obtrusiveness), less moment since center of gravity of mask is
closer to the patient's face, and/or improved line of sight.
[0203] 5. Modular Design
[0204] The mask system provides a modular design that allows
different styles and/or sizes of the frame (also referred to as a
frame module), shroud (also referred to as a shroud module),
cushion (also referred to as a cushion module), and/or elbow (also
referred to as an elbow module) to be interchanged or mixed and
matched with one another to provide a more customized mask system
for the patient. In addition, such design allows selected modules
to be easily replaced, e.g., treatment requirements change, worn
out or damaged, etc.
[0205] In an embodiment, the mask system may be provided with a
number of different cushions, e.g., each having cushions of
different styles and/or sizes (e.g., depending on patient
preference and/or fit). For example, the non-face contacting side
of each cushion may include a common or universal configuration for
interfacing with the frame, and the face-contacting side of the
cushion may include different styles and/or sizes. This provides a
modular arrangement that allows the frame to be selectively (e.g.,
and removably) coupled to one of multiple cushion. For example, the
different cushions may include different size cushions (e.g.,
small, medium, and large) and may include a different cushion
structures.
[0206] In an embodiment, the mask system may be provided with
different shrouds, e.g., each shroud having a different style
and/or size (e.g., shroud with different arrangement/style of
headgear connectors, shroud with forehead support, different
headgear vectors, etc).
[0207] In an embodiment, the mask system may be provided with
different frames, e.g., each frame having a different style and/or
size (e.g., frame with different vent arrangement, small, medium,
and large size frame, etc).
[0208] In an embodiment, the mask system may be provided with a
number of different elbows, e.g., each having a vent arrangement,
AAV (in the case of an oro-nasal mask), and/or elbow of different
styles and/or sizes. In the illustrated embodiment of FIGS. 27-30,
the vent arrangement 76 and AAV 85 are structured to be removably
attachable to the elbow 70. This provides a modular arrangement
that allows the elbow to be selectively and removably coupled to
one of multiple vent arrangements and/or AAVs. This also allows the
vent arrangement and AAV to be easily replaced, e.g., if
damaged.
[0209] 5.1 Shroud to Frame Connection
[0210] The shroud is mounted on the outer surface of the frame,
e.g., preferably with a tight, conforming fit on the frame.
[0211] 5.1.1 Upper Retaining Mechanism
[0212] In the illustrated embodiment of FIGS. 1-5, the shroud 1020
is connected to the frame 1040 by an upper retaining mechanism or
interfacing structure 1048 located on the top end of the frame and
shroud.
[0213] As shown in FIGS. 2 to 5, the upper retaining mechanism 1048
is in the form of two taper locks structured to secure the shroud
1020 on the frame 1040 and prevent unintentional disassembly
particularly due to headgear forces. In this embodiment, opposing
sides of the frame include a female slot 1055 adapted to receive a
respective tang protrusion (which tapers along its length) on the
underside of the shroud 1020. The tapered protrusion engages within
a respective female slot, e.g., with a friction fit.
[0214] FIGS. 10 to 19-4 show another embodiment of a mask system
1110 which more clearly illustrates an embodiment of the taper
lock. FIGS. 10 to 17 show various views of the frame 1140, shroud
1120, and elbow 1170 of the mask system 1110.
[0215] As best shown in FIGS. 11 to 13, opposing sides of the top
end of the frame 1140 include a platform 1154 which provides a
first female slot 1155(1). In addition, the space between the
platform 1154 and the outer surface of the frame 1140 defines a
second female slot 1155(2). As best shown in FIG. 17, opposing
sides of the top end of the shroud 1120 include a tang protrusion
1156 on the underside of the shroud 1120. The tang protrusion 1156
includes a first tang 1156(1) and a second tang 1156(2) that
extends generally transverse to the first tang 1156(1). As shown in
FIGS. 18-1 and 18-2, each tang may taper along its length, i.e.,
thinner towards its free end.
[0216] FIGS. 18-1 and 18-2 and 19-1 to 19-4 sequentially illustrate
attachment of the shroud 1120 to the frame 1140. As illustrated,
the tangs 1156(1), 1156(2) of each tang protrusion 1156 are
structured to engage with respective slots 1155(1), 1155(2), e.g.,
with a friction fit. As best shown in FIGS. 19-1 to 19-4, each slot
1155(2) includes lead-ins or guides 1157 that curve along their
length (i.e., extend in vertical and horizontal direction) so as to
guide the tang 1156(2) into the slot 1155(2) and aid assembly.
FIGS. 18-2 and 19-4 show the tangs 1156(1), 1156(2) when fully
inserted with respective slots 1155(1), 1155(2).
[0217] In an alternative embodiment, as shown in FIG. 20, the upper
retaining mechanism may include a clip-type arrangement. As
illustrated, opposing sides of the top end of the frame 1240
provide a shoulder 1255(1) and a tapered protrusion 1255(2).
Opposing sides of the top end of the shroud 1220 include a first
tang 1256(1) and a second tang 1256(2) on the underside of the
shroud 1220. In use, each first tang 1256(1) is engaged with the
respective shoulder 1255(1) and the second tang 1256(2) is engaged
or clipped onto the tapered protrusion 1255(2), e.g., with a
snap-fit.
[0218] 5.1.2 Lower Retaining Mechanism
[0219] In an embodiment, the shroud may also be connected to the
frame by a lower retaining mechanism located on the bottom end of
the frame and shroud. For example, a retaining mechanism may be
provided to the opening of the shroud which is structured to
interlock or otherwise engage with the opening of the frame.
[0220] For example, as shown in FIGS. 14, 15, 17, and 21, the
opening 1132 of the shroud 1120 may include structure adapted to
engage the collar 1149 surrounding the frame opening 1146 with a
snap-fit. As illustrated, the shroud 1120 includes snap fingers
1145(1) (e.g., three snap fingers) and sandwich tabs 1145(2) (e.g.,
three sandwich tabs) that extend from the opening 1132. The snap
fingers and sandwich tabs are alternatively spaced about the
opening.
[0221] In use, the snap fingers 1145(1) resiliently deflect (e.g.,
0.5 mm deflection) and engage respective part-annular protrusions
1149(1) provided to the collar 1149 (e.g., see FIGS. 22 and 23) to
provide an initial retention of the shroud 1120 to the frame 1140
(e.g., with allowable stresses), e.g., to facilitate assembly and
disassembly. In addition, as the snap fingers 1145(1) engage
respective protrusions 1149(1), the sandwich tabs 1145(2) are
received in respective recesses 1149(2) provided to the end of the
collar 1149 (e.g., see FIGS. 22 and 23). When the elbow 1170 is
engaged with the frame 1140 (e.g., see FIG. 23), an annular
protrusion 1171 on the elbow 1170 is positioned on an opposing side
of the sandwich tabs 1145(2) so that the sandwich tabs 1145(2) are
sandwiched between the collar 1149 and the elbow 1170. Thus, the
sandwich tabs utilize elbow retention forces to retain the shroud
on the frame during use. The elbow 1170 has a distal shoulder 1173
adapted to extend under the edge of the frame 1140 to retain the
elbow to the frame. The snap fingers 1145(1) allow the shroud to
connect to the frame independent of the elbow.
[0222] In an alternative embodiment, as shown in FIG. 24, the
shroud's lower section may be structured to clip to a single point
below the collar. As illustrated, the lower end of the shroud 1320
includes a snap finger 1345 that is engaged or clipped onto a
protrusion 1349(1) spaced below the collar 1349 of the frame 1340,
e.g., with a snap-fit. In this embodiment, the protrusion 1349
extends from the cover enclosing auxiliary ports. This arrangement
may facilitate molding of the collar on the frame, e.g., uniform
thickness of the collar prevents molding distortions. In addition,
removal of the protrusions 1149(1)/recesses 1449(2) from the collar
may reduce the risk of leak.
[0223] 5.1.3 Finger Grip
[0224] In an embodiment, the outer surface of the frame 1040 may
include finger grips or recessed portions 1097, which are
positioned to be exposed under the shroud 1020. The finger grips
are adapted to allow the patient an improved ability to grip the
frame and/or shroud which is particularly useful when disengaging
the shroud from the frame.
[0225] 5.1.4 Alternative Interfacing Structure
[0226] In an alternative embodiment, as shown in FIG. 27-30, the
shroud 20 includes an open construction that provides an annular or
part annular retaining portion 22 structured to retain the frame 40
and the elbow 70. As illustrated, the annular retaining portion 22
includes an interfacing structure 23 along an inner edge that is
adapted to interface with or otherwise removably connect to an
interfacing structure 48 along the outer perimeter of the frame 40
(e.g., see FIG. 28). In the illustrated embodiment, the interfacing
structure 23 is in the form of opposed flanges 23(1) that are
adapted to interlock with respective locking structures 48(1)
provided on opposing sides of the frame 40. However, other suitable
arrangements for attaching the frame 40 to the shroud 20 are
possible, e.g., friction fit, snap-fit, mechanical interlock, or
other suitable attachment mechanism.
[0227] For example, the frame 40 may be coupled to the shroud 20 in
a manner that allows the frame 40 to be locked in different angular
positions with respect to the shroud 20, e.g., pivotally
mounted.
[0228] 5.1.5 Alternative Upper Headgear Connector
[0229] FIGS. 40-1 to 40-7 illustrate a frame and a clip-on upper
headgear connector or rigidizer according to another embodiment of
the present invention.
[0230] The frame 442 includes an opening 449 adapted to engage a
frame shroud and/or elbow. Around and under the opening 449 is the
u-shaped slot 402 for gas washout and auxiliary ports 443 on each
side thereof.
[0231] In this embodiment, each upper side of the frame 442
includes a retaining member 433 and an upper intermediate portion
of the frame 442 includes retaining grooves 435, which are
structured and arranged to retain an upper headgear connector or
rigidizer 424.
[0232] As best shown in FIGS. 40-6 and 40-7, the upper headgear
connector 424 includes a pair of elongated arms or rigidizers 426
coupled by a pair of wire members 428. Each rigidizer 426 includes
a slot 427 at its free end adapted to receive a respective headgear
strap in use.
[0233] In use, the upper headgear connector 424 is adapted to clip
onto the frame 442 (e.g., see FIGS. 40-1 and 40-2). Specifically,
intermediate portions of the wire members 428 are received in
respective grooves 435 of the frame 442, and end portions of the
wire members 428 extend through respective retaining members 433
with the rigidizers 426 providing a shoulder to interlock with
respective retaining members 433. FIGS. 40-4 and 40-5 show an upper
portion of a retaining member 433 to illustrate the groove 433(1)
adapted to receive a respective wire. As illustrated, the end of
the groove 433(1) includes tapered side walls 433(2) and drops off
towards a rear side 433(3) to position the rigidizers 426 into
interlocking engagement with the retaining member 433.
[0234] FIGS. 41-1 to 41-12 illustrate an upper portion of a frame
and a clip-on upper headgear connector or rigidizer according to
another embodiment of the present invention.
[0235] As illustrated, the upper portion of the frame 542 includes
a retaining member 533 on each side thereof and a retaining groove
535 along an intermediate portion thereof, which are structured and
arranged to retain an upper headgear connector or rigidizer
524.
[0236] As best shown in FIGS. 41-5 and 41-12, the upper headgear
connector 524 includes a pair of elongated arms or rigidizers 526
coupled by a connecting portion 528. Each rigidizer 526 includes a
slot 527 at its free end adapted to receive a respective headgear
strap in use. In addition, the upper headgear connector 524
includes a clip structure 525 on each side of the connecting
portion 528.
[0237] In use, the upper headgear connector 524 is adapted to clip
onto the frame 542 (e.g., see FIGS. 41-1 and 41-2). Specifically,
the connecting portion 528 is received in the groove 535 of the
frame 542, and the clip structures 525 releasably interlock with
respective retaining members 533. As best shown in FIGS. 41-3 and
41-4, each retaining member 533 provides a cross-bar, and each clip
structure 525 provides a v-shaped configuration that is adapted to
resiliently deflect through the cross-bar and provide a shoulder to
releasably interlock with the cross-bar.
[0238] FIGS. 42-1 to 42-7 illustrate an alternative embodiment for
engaging the upper headgear connector with the frame. As
illustrated, each retaining member 533 provides an open-ended
cross-bar, and each clip structure 525 provides an elongated arm.
In this embodiment, the cross-bar is structured to resiliently
deflect to allow the clip structure 525 to extend through the
cross-bar and releasably engage the cross-bar, e.g., with a
friction fit. In addition, the upper headgear connector 524 of
FIGS. 42-1 to 42-7 includes a c-shaped clip structure 529 adapted
to interlock with a tab 549 provided to the frame 542 (see FIGS.
42-1 and 42-2).
[0239] 5.1.6 Grommet Attachment
[0240] FIGS. 44 and 45 illustrate an alternative mask arrangement
in which the shroud is attached to the frame via a grommet
[0241] For example, as shown in FIG. 44, the frame 740 includes a
grommet 745 (e.g., constructed of a rubber) and the shroud 720
includes an opening 725 adapted to receive the grommet 745 to
secure the shroud 720 to the frame 740. As illustrated, the shroud
720 includes elongated upper and lower arms 724, 726 each with a
slot 727 at its free end adapted to receive a respective headgear
strap in use.
[0242] FIG. 45 illustrates an alternative shroud 820 which includes
a single arm with a slot 827 at each end adapted to receive a
respective headgear strap in use. In addition, the shroud 820
provides an elongated inner slot 825 adapted to receive the grommet
745 of the frame 740. The elongated slot 825 allows the grommet 745
to be fixed in one of multiple positions along the length of the
slot 825, in contrast to the shroud 720 which provides a single
fixed position. In an embodiment, the shroud 820 may be slidable
with respect to the grommet 745 to allow an infinite number of
positions with respect to the frame 740.
[0243] In each embodiment, the grommet 745 (e.g., constructed of a
rubber) fixes the shroud in position but the inherent flexibility
of the grommet provides a flexible connection to decouple the
shroud from the frame and allow a range of movement between the two
components, e.g., like a ball joint or gimbal. Such arrangement
helps with fitting and sealing of the mask to the patient's face.
That is, the flexible connection allows the mask to selectively
adjust and/or self-fit with the patient's face.
[0244] 5.2 Cushion to Frame Connection
[0245] In FIGS. 1-8, the non-face contacting side of the cushion
1060 is connected to frame 1040 in a tongue and groove
relationship. The tongue 1066 (see FIGS. 1C, 1D, and 8) of the
cushion 1060 is inserted within a groove 1041 (see FIGS. 1C and 1D)
provided along the perimeter of the frame 1040. The tongue and
groove relationship may also include a locking lip or sealing lip
1068 (see FIGS. 1C, 1D, and 8) on the cushion that is adapted to
interlock with an undercut bead 1042 (see FIGS. 1C and 1D) within
the frame groove to fixably retain the cushion to the frame.
[0246] In the illustrated embodiment, the cushion 1060 also
includes one or more positioning features located around its
circumference to assist with proper alignment of the cushion with
the frame 1040. As shown in FIG. 7, the cushion 1060 includes
notches and/or protrusions (e.g., two notches 1067 and one
protrusion 1069) adapted to engage with complementary features in
the frame, e.g., interlocking relationship.
[0247] 5.2.1 Co-Molding Frame and Cushion
[0248] In an embodiment, as shown in FIGS. 27-30, the frame 40 and
cushion 44 may be co-molded with one another to form a one-piece,
integrated component. For example, the frame 40 may be molded of a
first material adapted to interface with the shroud 20 and the
cushion 44 may be co-molded onto the frame 40 of a second material
adapted to interface with patient's face.
[0249] In such embodiment, the cushion 44 may be constructed of a
relatively soft elastomeric material (e.g., silicone) for sealing
and the frame 40 may be constructed of a more rigid material than
the cushion 44 (e.g., polycarbonate, polypropylene) for interfacing
with the frame.
[0250] Co-molding the frame 40 to the cushion 44 provides a
chemical bond without necessarily forming a mechanical interlock.
As a result, the connection includes no cracks, a gas tight seal,
and clean interface. Moreover, such co-molded connection relaxes
tolerances as the mold materials are sufficiently flexible to fill
in any gaps at the interface between the frame 40 and the cushion
44. Also, the co-molded frame/cushion provides a reduced part count
(reduced cost) and facilitates assembly/disassembly to the shroud
20.
[0251] In an alternative embodiment, as shown in FIG. 33, the frame
40 and cushion 44 may be integrally formed in one piece, e.g., of a
silicone material. That is, the frame 40 may have the same shape
and structure as described above, but be integrally molded of the
same material, e.g., silicone.
[0252] In an embodiment, the integrally formed frame 40/cushion 44
may be co-molded to the shroud 20, e.g., constructed of
polycarbonate or polypropylene. For example, the shroud 20 may be
constructed of a relatively rigid material (e.g., polycarbonate or
polypropylene) and the frame 40/cushion 44 may be co-molded onto
the shroud 20 of a relatively soft elastomeric material (e.g.,
silicone).
[0253] 5.3 Vent Arrangement
[0254] In FIGS. 1, 1B, 1C, 1D, and 2-5, the vent arrangement 1076
is provided to the frame and includes a plurality of holes 1077
(e.g., 5-100 holes, e.g., 20-50 holes, or about 35 holes) oriented
at an angle (e.g., 45.degree.) on the outer surface of the frame so
as ensure the exhausted air is directed away from the patient and
preferably their bed partner when the patient is sleeping. As shown
in FIGS. 1C and 1D, each hole 1077 may include a contour or taper
along its length. However, it should be appreciated that the vent
arrangement may include other suitable arrangements, e.g.,
different number of holes, hole arrangement, positioning on frame,
vent provides part pf interlocking structure with shroud, etc.
[0255] FIG. 35-1 illustrates a vent arrangement 276 provided to the
frame 240 for gas washout. In the illustrated embodiment, the vent
arrangement 276 is in the form of a vent insert (e.g., elastomeric
vent insert) that is adapted to be removably supported within an
outlet opening in the frame 240. The vent insert may be similar
those described in U.S. Pat. Nos. 6,561,190, 6,561,191, and
7,207,335, each of which is incorporated herein by reference in its
entirety. However, it should be appreciated that the vent
arrangement may have other suitable forms (e.g., vent holes in main
body, etc.).
[0256] FIGS. 37-3, 39-2, and 39-4 illustrate a frame 340 that
includes a u-shaped slot 302 that receives a u-shaped plug-type
vent 305 for gas washout. As illustrated, the plug-type vent 305
wraps around and under the opening in the frame 340 for the elbow
370. The plug-type vent 305 includes a plurality of tracks or
grooves 307 on each side thereof. In use, the grooved plug-type
vent 305 forms a seal with the slot 302 so that exhausted air can
exit between the slot walls and the grooves 307 on the plug-type
vent 305. In an embodiment, the port caps 347 may be integrated or
incorporated into the plug-type vent 305 (e.g., integrally formed
in one piece). Further details of such a plug-type vent arrangement
are provided in U.S. patent application Ser. No. 12/230,120, filed
Aug. 22, 2008, which is incorporated herein by reference in its
entirety. FIGS. 39-2 to 39-6 show the frame 340 with the grooved
plug-type vent 305 removed so as to more clearly illustrate the
u-shaped slot 302 and auxiliary ports 343 on each side thereof.
[0257] Also, it should be appreciated that the vent arrangement may
be provided to the elbow. For example, a shown in FIGS. 27-30, the
vent arrangement 76 is in the form of a vent insert that is adapted
to be removably supported within an outlet opening in the elbow 70.
In an embodiment, the vent arrangement 76 includes a base adapted
to be supported within the outlet opening, one or more grill
components or media (e.g., filter, membrane, or other porous
material) provided to the base and structured to diffuse vent flow,
and a cover to maintain the grill components/media within the base.
Only the cover 77 of the vent arrangement 76 is visible in FIGS.
27-30.
[0258] Exemplary embodiments of such a vent arrangement are
disclosed in U.S. patent application Ser. No. 12/230,120, filed
Aug. 22, 2008, which is incorporated herein by reference in its
entirety.
[0259] However, it should be appreciated that the vent arrangement
may include other suitable arrangements, e.g., vent insert with one
or more vent holes.
[0260] Also, the elbow may provide an alternative venting
arrangement to the vent insert. For example, as indicated in dashed
lines in FIG. 30, the first end portion 74(1) of the elbow 70
(e.g., along the interfacing structure 75) may include one or more
vent holes 276 for gas washout. The one or more holes 276 may be
provided to a soft part (e.g., silicone seal as described below)
and/or a hard part (e.g., polycarbonate, polypropylene) of the
elbow. The holes 276 may extend around the entire perimeter of the
first end portion 74(1) or may extend along one or more portions of
the first end portion 74(1). It is noted that providing vent holes
along the entire perimeter of the elbow may help to disperse the
vent flow in use. However, other suitable hole arrangements, hole
numbers, and/or hole shapes along the first end portion 74(1)
and/or other portions of the elbow are possible.
[0261] 5.4 Ports
[0262] In FIGS. 1-5, the base of the frame 1040 includes two ports
1043 positioned so that in use, oxygen or other breathable gas can
be delivered close to the patient's nares or pressure monitoring
equipment can be attached. The ports 1043 may also be used to
attach additional medical equipment such as pressure or flow
sensors. The ports may be selectively closable or sealable by a
ports cap.
[0263] In an alternative embodiment, as shown in FIGS. 25 and 26,
the frame 1040 may include a side port 1043.1, e.g., in addition to
or as an alternative to the ports 1043.
[0264] FIGS. 35-1 and 35-2 show a frame 240 that includes an
auxiliary port or spigot 243 on an upper portion of the frame,
e.g., for supplemental oxygen, measurement device, etc.
[0265] In FIGS. 37-1 to 37-3 and 39-1 to 39-6, the frame 340
includes an auxiliary port or spigot 343 on each side thereof,
e.g., for supplemental oxygen, measurement device, etc. Port caps
347 are provided to seal respective ports 343.
[0266] 6. Interface Seal
[0267] In an embodiment, a seal may be provided at the interface
between the elbow and the shroud, at the interface between the
frame and the shroud, and/or at the interface between the elbow and
the frame. For example, a seal (e.g., elastomeric, ring-shaped
seal) may be formed separately from the modules and attached at the
interface (e.g., sandwiched between modules, adhesive, etc.).
Alternatively, a seal may be co-molded with one or more of the
modules. In an embodiment, a silicone lip seal may be provided to
the frame to seal against the elbow, thereby reducing leak.
[0268] In another embodiment, as shown in FIG. 27-30, the
interfacing structure 75 of the elbow 70 may be constructed of a
relatively soft, sealing material (e.g., silicone, which may be
co-molded to the harder material of the elbow) that is structured
to provide a seal at the interface between the elbow 70 and the
shroud 20. Also, the relatively soft interfacing structure 75
(e.g., silicone) provides a "soft" attachment to the relatively
hard shroud 20 (e.g., polycarbonate, polypropylene) which may allow
an interference type fit. As noted above, one or more vent holes
may be provided to the softer interfacing structure and/or the
harder elbow.
[0269] While the invention has been described in connection with
what are presently considered to be the most practical and
preferred embodiments, it is to be understood that the invention is
not to be limited to the disclosed embodiments, but on the
contrary, is intended to cover various modifications and equivalent
arrangements included within the spirit and scope of the invention.
Also, the various embodiments described above may be implemented in
conjunction with other embodiments, e.g., aspects of one embodiment
may be combined with aspects of another embodiment to realize yet
other embodiments. Further, each independent feature or component
of any given assembly may constitute an additional embodiment.
Furthermore, each individual component of any given assembly, one
or more portions of an individual component of any given assembly,
and various combinations of components from one or more embodiments
may include one or more ornamental design features. In addition,
while the invention has particular application to patients who
suffer from OSA, it is to be appreciated that patients who suffer
from other illnesses (e.g., congestive heart failure, diabetes,
morbid obesity, stroke, bariatric surgery, etc.) can derive benefit
from the above teachings. Moreover, the above teachings have
applicability with patients and non-patients alike in non-medical
applications.
* * * * *