Hollow structure for respiratory mask cushion

Patent metadata

Field	Value
Publication number	US-9642977-B2
Application number	US-201313963073-A
Country	US
Kind code	B2
Filing date	Aug 9, 2013
Priority date	Aug 10, 2012
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

The present invention provides a method for producing a filled hollow structure, preferably a cushion for a breathing mask. According to said method, a hollow structure of a first material having a cavity is produced, wherein the hollow structure has an inlet to and an outlet from the cavity. The hollow structure is positioned on a tool for holding the hollow structure. Subsequently a second material is inserted through the inlet into the cavity, while gas present in the cavity can escape through the outlet. Finally, the inlet and/or the outlet is sealed. During the step of inserting the second material through the inlet into the cavity the outlet resists flow of said second material.

First claim

The invention claimed is:

1. Method for producing a filled hollow structure, comprising:
a) producing a hollow structure of a first material having a cavity, the hollow structure having an inlet to and an outlet from the cavity, the inlet and outlet being separate and spaced from one another;
b) positioning the hollow structure on a tool for holding the hollow structure;
c) inserting a second material through the inlet into the cavity, while at the same time allowing gas present in the cavity to escape through the outlet; and
d) sealing the inlet and/or the outlet;
wherein the outlet resists or prevents flow of the second material through the outlet during insertion of the second material into the cavity.

2. Method according to claim 1 , wherein the inlet and/or outlet comprises a membrane, which has an orifice in the shape of a crossed slot.

3. Method according to claim 1 , wherein the second material has a viscosity in a range between 50 and 2000 MPas at 25° C. (DIN EN ISO 3219).

4. Method according to claim 1 , wherein the inserted material is distributed within the cavity by means of gravity.

5. Method according to claim 1 , wherein the hollow structure is pivoted or tilted during inserting the second material in order to completely fill the cavity with the second material.

6. Method according to claim 1 , further comprising sealing the inlet and/or outlet by curing and/or hardening the second material.

7. Method according to claim 1 , further comprising sealing the inlet and/or outlet by applying a sealing material.

8. Method according to claim 1 , wherein the first material consists of or comprises one or a combination of silicone, polysiloxane, silicone foam, silicone rubber and thermoplastic polymers.

9. Method according to claim 1 , wherein the second material consists of or comprises one or a combination of gel, foam, liquid, gas, beads and silicone.

10. Method according to claim 1 , wherein the shore hardness of the second material lies in a range between 10 and 20 according to DIN 53505.

11. Method according to claim 1 , further comprising removing the hollow structure from the tool by using compressed air.

12. Method according to claim 1 , wherein the second material is inserted into the cavity under pressure and/or vacuum.

13. Method according to claim 1 , wherein the hollow structure is a cushion for a breathing mask.

14. Method according to claim 1 , wherein the inlet and/or outlet comprises a membrane, which is adapted to be punctured.

15. Method according to claim 14 , further comprising puncturing the membrane before inserting the second material through the inlet.

16. Method according to claim 14 , wherein the membrane comprises a predetermined breaking point in the form of a crossed slot, a cross recess, a weakened region or a perforation.

17. Method according to claim 14 , wherein the membrane allows for venting, yet resists or prevents, flow of the second material during insertion into the cavity.

18. Method according to claim 14 , wherein the membrane prevents flow of the second material if exposed to a pressure up to 3 hPa.

19. Method according to claim 14 , wherein the membrane prevents flow of a material having a viscosity in a range between 50 and 2000 MPas at 25° C. (DIN EN ISO 3219) if exposed to a pressure up to 3 hPa.

20. Method according to claim 14 , wherein the flow rate of a material having a viscosity in a range between 50 and 2000 MPas at 25° C. (DIN EN ISO 3219) if exposed to a pressure up to 3 hPa through the membrane is smaller than 100 mm 3 /s.

21. Method according to claim 14 , wherein the membrane has a diameter of less than 5 mm.

22. Method according to claim 14 , wherein the orifice of the membrane or the opening in the membrane created by puncturing the membrane has a diameter of less than 4 mm.

23. Hollow structure made of a first material having a cavity, the structure comprising an inlet for inserting a second material into the cavity and an outlet for gas present in the cavity to escape, the outlet being separate from and spaced from the inlet, wherein the inlet and/or outlet comprises a membrane, which is adapted to be punctured and/or which has an orifice.

24. Hollow structure according to claim 23 , wherein the punctured membrane and/or the orifice has a structure adapted to bias the membrane to a closed position.

25. Hollow structure according to claim 23 , wherein the orifice has the shape of a crossed slot.

26. Hollow structure according to claim 23 , wherein the membrane comprises a predetermined breaking point in the form of a crossed slot, a cross recess, a weakened region or a perforation.

27. Hollow structure according to claim 23 , wherein the punctured membrane and/or the orifice of the membrane allows for venting, yet resists flow of a material having a viscosity in a range between 50 and 2000 MPas, at 25° C. (DIN EN ISO 3219) if exposed to a pressure up to 3 hPa.

28. Hollow structure according to claim 23 , wherein the flow rate of a material having a viscosity in a range between 50 and 2000 MPas at 25° C. (DIN EN ISO 3219) if exposed to a pressure up to 3 hPa through the (punctured) membrane is smaller than 100 mm 3 /s.

29. Hollow structure according to claim 23 , wherein the membrane has a diameter of less than 5 mm.

30. Hollow structure according to claim 23 , wherein the orifice of the membrane or the opening in the membrane created by puncturing the membrane has a diameter of less than 4 mm.

31. Hollow structure according to claim 23 , wherein the self-healing membrane comprises a predetermined breaking point, preferably a crossed slot, a cross recess, a weakened region or a perforation.

32. Cushion for a respiratory mask comprising a hollow structure according to claim 23 , wherein the cavity is filled with the second material.

33. Hollow structure according to claim 23 , wherein the outlet orifice has a size that is smaller than a size of the inlet orifice.

34. Hollow structure according to claim 23 , wherein the inlet and outlet are structured such that gas present in the cavity escapes at the same time as the second material is introduced into the cavity.

35. Hollow structure according to claim 23 , wherein the outlet is structured to allow flow of gas but resist flow of the second material.

36. Hollow structure made of a first material having a cavity, the structure comprising an inlet for inserting a second material into the cavity and an outlet for gas present in the cavity to escape, the outlet being separate and spaced away from the inlet, wherein the inlet and/or outlet comprises a self-healing membrane.

37. Hollow structure according to claim 36 , wherein the self-healing membrane is adapted to be punctured in such a manner as to allow for the puncture site to self-seal upon insertion of the second material into the cavity.

38. Hollow structure according to claim 36 , wherein the self-healing membrane is adapted to be punctured by a puncturing tool in such a manner as to allow for the puncture site to self-seal upon removal of the puncturing tool.

39. Hollow structure according to claim 38 , wherein the punctured membrane and/or the orifice has a structure adapte

Assignees

• Resmed R&D Germany Gmbh
• Resmed Ltd

Inventors

• Nickol Johannes
• Rothfuss Jens
• Burz Sebastian
• Eibl Robert
• Lang Bernd

Classifications

• Y10T428/1352

  Polymer or resin containing [i.e., natural or synthetic] · CPC title

• B29D22/00 Primary

  Producing hollow articles (tubular articles B29D23/00; pneumatic tyres B29D30/00) · CPC title

• A61M16/0622

  having an underlying cushion · CPC title

• A61M16/06 Primary

  Respiratory or anaesthetic masks · CPC title

• A61M16/0616

  with face sealing means comprising a flap or membrane projecting inwards, such that sealing increases with increasing inhalation gas pressure · CPC title