Mask system with snap-fit shroud

Patent metadata

Field	Value
Publication number	US-9757533-B2
Application number	US-201313964280-A
Country	US
Kind code	B2
Filing date	Aug 12, 2013
Priority date	Mar 4, 2008
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

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.

First claim

What is claimed is:

1. A mask system to provide positive air pressure therapy to a patient, the mask system comprising:
a cushion module comprising:
a frame having an internal surface forming a breathing chamber, the frame including a circular frame opening positioned to receive a supply of air at positive pressure, the frame including a cylindrical collar, the collar surrounding said frame opening, the collar projecting from an external surface of the frame in a direction away from the breathing chamber, the collar having a longitudinal axis, the collar having a cylindrical surface and a plurality of protrusions that protrude radially relative to the cylindrical surface, and the protrusions being spaced from one another about the circumference of the cylindrical surface of the collar, wherein the frame, including the cylindrical collar and the plurality of protrusions, is constructed of a first material,
a cushion constructed of an elastomeric material that is a different material from the first material, the first material being harder than the elastomeric material of the cushion, the frame being more rigid than the cushion, the cushion configured to seal against the patient's face in use to enable the supply of air at positive pressure to be delivered to at least the patient's nose, and
a protruding vent arrangement having a plurality of holes for gas washout from the breathing chamber to atmosphere, the protruding vent arrangement including a vent-wall having the plurality of holes, the vent-wall being spaced from an adjacent portion of the frame by a lower wall and two lateral side walls of the protruding vent arrangement, and the protruding vent arrangement positioned above the frame opening,
wherein the cushion and the frame are joined to form a one-piece, integrated component;

headgear configured to maintain the cushion module in position on the patient's head in use;
an elbow configured to receive the supply of air at positive pressure and deliver the supply of air at positive pressure to the breathing chamber; and
a shroud removably connected to the cushion module, the shroud having a vent-receiving opening that receives the protruding vent arrangement, wherein the shroud includes a circular elbow opening that accommodates the elbow, wherein the shroud includes a rear surface that at least partly covers the external surface of the frame of the cushion module and the shroud includes a plurality of snap fingers, the plurality of snap fingers being circumferentially spaced about the elbow opening, and the plurality of snap fingers projecting from the rear surface of the shroud in a direction towards the breathing chamber, wherein the shroud, including the plurality of snap fingers, is constructed of a second material, the second material of the shroud being harder than the elastomeric material of the cushion, the shroud being more rigid than the cushion, and wherein the shroud includes a pair of upper headgear connectors and a pair of lower headgear connectors, said pair of upper headgear connectors structured to connect to said headgear, and said pair of lower headgear connectors structured to connect to said headgear via clips,
wherein, to removably connect the shroud and the cushion module, the plurality of snap fingers are structured to resiliently deflect in a radial direction relative to the longitudinal axis of the collar to form a removable snap-fit connection with corresponding ones of the plurality of protrusions of the collar by moving the cushion module and the shroud towards one another along the longitudinal axis of the collar.

2. The mask system of claim 1 , wherein the cushion is constructed to engage the patient's face along a nasal bridge region, a cheek region, and a lower lip/chin region of the patient's face when in use, and wherein the elbow includes an anti-asphyxia valve.

3. The mask system of claim 1 , wherein the elastomeric material of the cushion is silicone.

4. The mask system of claim 1 , wherein the cushion and the frame are constructed and arranged to be in an interlocking relationship with one another.

5. The mask system of claim 1 , wherein the cushion includes notches and/or protrusions to engage with complementary features in the frame.

6. The mask system of claim 1 , wherein the first material is polycarbonate.

7. The mask system of claim 1 , wherein the shroud comprises a forehead support.

8. The mask system of claim 1 , wherein:
the cushion is constructed to engage the patient's face along a nasal bridge region, a cheek region, and a lower lip/chin region of the patient's face when in use,
the elastomeric material of the cushion is silicone,
the cushion and the frame are constructed and arranged to be in an interlocking relationship with one another,
the first material is polycarbonate,
the second material is polycarbonate,
said headgear comprises hook and loop material,
the shroud further comprises a forehead support,
the elbow includes an anti-asphyxia valve,
the elbow and the shroud are configured to be directly connected to one another,
each of the plurality of snap fingers and each of the plurality of protrusions have a part-annular shape that is curved relative to the longitudinal axis of the collar,
a region of the cushion positioned to engage the nasal bridge region of the patient is configured to allow increased movement compared to another region of the cushion that is adapted to seal with another region of the patient's face, and
the mask system being constructed so that the snap-fit connection is established when a force is applied to move the shroud and cushion module toward one another along the longitudinal axis until a ramped rear end of each of the snap fingers initially contacts a front end of the corresponding protrusion on the collar, whereupon further application of the force causes each of the snap fingers to ride over the corresponding protrusion and therefore resiliently deflect in a first radial direction, and upon further movement towards one another, each of the snap fingers resiliently moves in a second radial direction, opposite the first radial direction, and engages a rear end of the corresponding protrusion to snap each of the snap fingers into place, thereby removably connecting the shroud and the cushion module.

9. The mask system of claim 8 , the cushion further comprising a fold configured to deform at the nasal bridge region of the patient in use.

10. The mask system of claim 8 , wherein the elbow is attached to the shroud with a mechanical interlock.

11. A system for treating a patient with sleep disordered breathing, comprising:
the mask system of claim 8 ;
a flow generator to generate a supply of air at positive pressure to be delivered to the mask system; and
an air delivery tube configured to deliver the supply of air from the flow generator to the mask system.

12. The mask system of claim 1 , wherein the vent-receiving opening is bounded by a rim of the shroud, wherein the rim lies proximate the two lateral side walls and the lower wall of the vent-wall of the protruding vent arrangement when the shroud is snap-fit connected to the cushion module such that the protruding vent arrangement partly interlocks the frame and the shroud, and wherein the vent-wall is substantially flush with a portion of the shroud surrounding the rim.

13. The mask system of claim 1 , wherein the vent-wall is oriented at an angle relative to the frame opening such that a longitudinal axis of each of the plurality of holes and the longitudinal axis of the collar are not parallel.

14. The mask system of claim 1 , wherein the plurality of snap fingers are

Assignees

• Resmed Ltd

Inventors

• Ng Eva
• Lockwood David James
• Wehbeh Jamie Graeme
• Valcic Zoran
• D'Souza Errol Savio Alex
• Eves Matthew
• Sari Mahsita

Classifications

• A61M16/0616

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

• A61M2016/0661

  with customised shape · CPC title

• A61M16/0694

  Chin straps · CPC title

• A61M16/0622 Primary

  having an underlying cushion · CPC title

• A61M16/0683

  Holding devices therefor · CPC title