PATIENT INTERFACE

BACKGROUND
Field

The present disclosure relates to respiratory therapy systems. In particular, the disclosure relates to interface assemblies for use in respiratory therapy and portions thereof.

Description of Related Art

Respiratory masks are used to provide respiratory therapy to the airways of a person suffering from any of a number of respiratory illnesses or conditions. Such therapies may include but are not limited to continuous positive airway pressure (CPAP) therapy and non-invasive ventilation (NIV) therapy.

CPAP therapy can be used to treat obstructive sleep apnea (OSA), a condition in which a patient's airway intermittently collapses, during sleep, preventing the patient from breathing for a period of time. The cessation of breathing, or apnea, results in the patient awakening. Repetitive and frequent apneas may result in the patient rarely achieving a full and restorative night's sleep.

CPAP therapy involves the delivery of a supply of continuous positive air pressure to the airway of the patient via a respiratory mask. The continuous positive pressure acts as a splint within the patient's airway, which secures the airway in an open position such that the patient's breathing and sleep are not interrupted.

Respiratory masks typically comprise a patient interface and a headgear, wherein the patient interface is configured to deliver the supply of continuous positive air pressure to the patient's airway via a seal or cushion that forms an airtight seal in or around the patient's nose and/or mouth. Respiratory masks are available in a range of styles including full-face, nasal, direct nasal and oral masks, which create an airtight seal with the nose and/or mouth. The seal or cushion is held in place on the patient's face by the headgear. In order to maintain an airtight seal the headgear should provide support to the patient interface such that it is held in a stable position relative to the patient's face during use. Such respiratory masks may also be used to deliver NIV and other therapies.

SUMMARY

The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized.

In some configurations, a respiratory mask includes a frame configured to connect to headgear. The frame comprises a front wall having a vent and a gas inlet opening. The frame further comprises a collar extending away from the front wall. The collar surrounds the vent and the gas inlet opening. A cushion module comprises a housing and a cushion. The housing is made of a material more rigid than the cushion. The housing forms at least a portion of a breathing chamber of the respiratory mask. The housing defines a connection opening. A friction coupling is configured to selectively couple the connection opening of the cushion module to the collar of the frame such that a flow of gas can be delivered to the breathing chamber through the gas inlet opening of the frame and the connection opening of the cushion module. The friction coupling comprises an elastomeric friction member coupled to a portion of the housing that defines the connection opening.

In some configurations, the mask further comprises a divider wall within an interior of the collar. The divider wall having a first end and a second end, each connected to the collar. The divider wall separates the vent and the gas inlet opening.

In some configurations, a surface of the divider wall adjacent the vent extends substantially in a direction of gas flow through the vent.

In some configurations, the collar and the divider wall cooperate to define a socket configured to receive an elbow.

In some configurations, the mask further comprises an elbow received by the socket, wherein the elbow has a swivel connection with the frame.

In some configurations, the collar extends rearwardly from the front wall of the frame to a rearward edge. A rearward edge of the divider wall is positioned between the front wall of the frame and the rearward edge of the collar.

In some configurations, the frame forms at least a portion of the breathing chamber.

In some configurations, a space defined by an interior surface of the collar, an upper surface of the dividing wall and an interior surface of a vent wall portion of the front wall forms at least a portion of the breathing chamber.

In some configurations, the collar comprises an internal surface and an engagement surface, wherein the engagement surface engages with the friction member.

In some configurations, the collar further comprises a rim.

In some configurations, the friction member comprises an internal engagement surface and a peripheral surface.

In some configurations, the connection opening is defined by a support wall, wherein the support wall is disposed within the friction member and the housing extends through the peripheral surface of the friction member.

In some configurations, the cushion module further comprises a support flange that extends along a length of and supports the friction member.

In some configurations, the support flange is embedded within the friction member.

In some configurations, a portion of the housing disposed within the friction member comprises a plurality of apertures.

In some configurations, the friction member extends through each of the plurality of apertures.

In some configurations, a portion of the housing disposed within the friction member comprises a plurality of apertures and the friction member extends through each of the plurality of apertures, wherein at least a portion of the apertures are located between the support wall and the peripheral surface.

In some configurations, at least a portion of the apertures are located on the support flange.

In some configurations, the friction member defines an abutment surface that contacts the front wall of the frame when the cushion module is coupled to the frame.

In some configurations, the friction member defines a first length, the support flange defines a second length, an unsupported portion of the friction member that extends beyond the support flange defines a third length, and the collar defines a fourth length.

In some configurations, the first length is equal to the sum of the second length and the third length.

In some configurations, the first length is greater than the sum of the second length and the third length.

In some configurations, the first length is less than the sum of the second length and the third length.

In some configurations, the friction member defines a first thickness, the support flange defines a second thickness, a portion of the friction member located outside of the support flange defines a third thickness, a portion of the friction member located inside of the support flange defines a fourth thickness, and the collar defines a fifth thickness.

In some configurations, the first thickness equals the sum of the second thickness, the third thickness, and the fourth thickness.

In some configurations, the third thickness and the fourth thickness are equal.

In some configurations, the second thickness is equal to each of the third thickness and the fourth thickness.

In some configurations, the fourth thickness is greater than or equal to the third thickness.

In some configurations, the fourth thickness is less than or equal to the third thickness.

In some configurations, the second thickness and the fifth thickness are equal.

In some configurations, the second thickness is greater than the fifth thickness.

In some configurations, the second thickness is less than the fifth thickness.

In some configurations, the second thickness is less than or equal to either one of the third thickness and the fourth thickness.

In some configurations, the second thickness is greater than or equal to either one of the third thickness and the fourth thickness.

In some configurations, the first thickness is greater than or equal to the fifth thickness.

In some configurations, the first thickness is less than or equal to the fifth thickness.

In some configurations, the fourth thickness varies along the length of the friction member.

In some configurations, fourth thickness varies along the length of the friction member from a minimum near a proximal end of the friction member to a maximum near a distal end of the friction member.

In some configurations, the fourth thickness varies along the length of the friction member from a maximum near a proximal end of the friction member to a minimum near a distal end of the friction member.

In some configurations, the third thickness is zero.

In some configurations, a portion of the friction member that overlaps with the collar defines an overlap length.

In some configurations, the overlap length is greater than or equal to the third length.

In some configurations, the overlap length is greater than or equal to a sum of the second length and the third length.

In some configurations, the overlap length is less than the third length.

In some configurations, the overlap length is less than a sum of the second length and the third length.

In some configurations, the overlap length equals the fourth length.

In some configurations, the overlap length is less than the fourth length.

In some configurations, the overlap length is greater than the fourth length.

In some configurations, a portion of the friction member that does not overlap with the collar defines a non-overlap length and a portion of the front wall adjacent the support flange defines a first front wall thickness.

In some configurations, a sum of the first length and the first front wall thickness equals a sum of the overlap length and the non-overlap length.

In some configurations, a sum of the first length and the first front wall thickness is greater than a sum of the overlap length and the non-overlap length.

In some configurations, a sum of the first length and the first front wall thickness is less than a sum of the overlap length and the non-overlap length.

In some configurations, the support flange comprises a plurality of apertures and the friction member extends through each of the plurality of apertures. A distance between the portion of the front wall and a point on the plurality of apertures furthest from the portion of the front wall defines an aperture offset distance.

In some configurations, the non-overlap length is greater than or equal to a sum of the aperture offset distance and the first front wall thickness.

In some configurations, the non-overlap length is less than or equal to a sum of the aperture offset distance and the first front wall thickness.

In some configurations, a sum of the second length and the third length is greater than or equal to a sum of the overlap length and the aperture offset distance.

In some configurations, a sum of the second length and the third length is less than or equal to a sum of the overlap length and the aperture offset distance.

In some configurations, a sum of the overlap length and the aperture offset distance is less than or equal to first length.

In some configurations, a sum of the overlap length and the aperture offset distance is greater than or equal to first length.

In some configurations, a relative angle is defined between the collar and at least one of the support flange and a surface of the friction member that engages the collar in a direction of assembly of the cushion module to the frame.

In some configurations, the collar is angled relative to the direction of assembly.

In some configurations, at least one of the support flange and the surface of the friction member that engages the collar is angled relative to the direction of assembly.

In some configurations, a relative angle is defined between the collar and a surface of the friction member that engages the collar in a direction of assembly of the cushion module to the frame.

In some configurations, the collar is angled relative to the direction of assembly.

In some configurations, the surface of the friction member that engages the collar is angled relative to the direction of assembly.

In some configurations, the friction coupling is configured such that a force acting to compress the friction member is equal along a length of the collar.

In some configurations, the friction coupling is configured such that a force acting to compress the friction member is unequal along a length of the collar.

In some configurations, the force is larger at a location closer to the front wall relative to a location further from the front wall.

In some configurations, the force is smaller at a location closer to the front wall relative to a location further from the front wall.

In some configurations, a rearward-most extent of the friction member is at or forward of the front wall.

In some configurations, a rearward-most extent of the friction member is rearward of the front wall such that a portion of the friction member is located adjacent each of a forward surface and a rearward surface of the front wall.

In some configurations, the portion of the friction member adjacent the forward surface of the front wall has a surface that is aligned with a surface of the portion of the friction member adjacent the rearward surface of the front wall.

In some configurations, the connection opening is defined by a support wall. The support wall is disposed within the friction member such that the friction member is coupled to the cushion module.

In some configurations, the collar defines a collar length, the support wall defines a support wall thickness, and the friction member defines a total friction member length, a forward length forward of the support wall and a rearward length rearward of the support wall.

In some configurations, the total friction member length is equal to a sum of the forward length, the rearward length and the support wall thickness.

In some configurations, the total friction member length is greater than a sum of the forward length, the rearward length and the support wall thickness.

In some configurations, the total friction member length is less than a sum of the forward length, the rearward length and the support wall thickness.

In some configurations, the collar defines a collar thickness and the friction member defines a total thickness, a supported thickness along the support wall and an unsupported thickness inwardly of the support wall.

In some configurations, the total thickness equals a sum of the supported thickness and the unsupported thickness.

In some configurations, the total thickness equals twice the supported thickness.

In some configurations, the total thickness equals twice the unsupported thickness.

In some configurations, the supported thickness is equal to the unsupported thickness.

In some configurations, the supported thickness is greater than or equal to the unsupported thickness.

In some configurations, the supported thickness is less than or equal to the unsupported thickness.

In some configurations, the total thickness is greater than or equal to the collar thickness.

In some configurations, the total thickness is less than or equal to the collar thickness.

In some configurations, a portion of the friction member that overlaps with the collar defines an overlap length, a portion of the friction member that does not overlap with the collar defines a non-overlap length and a distance between a rearward end of the collar and the support wall along the direction of assembly defines a support wall offset distance.

In some configurations, the overlap length is greater than or equal to the support wall offset distance.

In some configurations, the overlap length is less than the support wall offset distance.

In some configurations, the overlap length is greater than or equal to the non-overlap length.

In some configurations, the overlap length is less than the non-overlap length.

In some configurations, the non-overlap length is greater than or equal to a sum of the support wall offset distance and the support wall thickness.

In some configurations, the non-overlap length is less than or equal to a sum of the support wall offset distance and the support wall thickness.

In some configurations, the overlap length equals the collar length.

In some configurations, the overlap length is less than the collar length.

In some configurations, the overlap length is greater than the collar length.

In some configurations, the total friction member length equals a sum of the overlap length and the non-overlap length.

In some configurations, the overlap length is less than the forward length.

In some configurations, the overlap length is greater than or equal to the forward length.

In some configurations, the overlap length is greater than or equal to a sum of the forward length, the rearward length and the support wall thickness.

In some configurations, the overlap length is less than or equal to a sum of the forward length, the rearward length and the support wall thickness.

In some configurations, the support wall thickness is less than or equal to the rearward length.

In some configurations, the support wall thickness is greater than the rearward length.

In some configurations, the housing comprises a wall portion external of the friction member and extending between the friction member and the cushion.

In some configurations, at least a surface of the friction coupling that engages the collar has a frosted or textured surface finish.

In some configurations, the elastomeric friction member comprises a lip configured to contact the collar to enhance a seal between the collar and the elastomeric friction member.

In some configurations, the lip is oriented at an oblique rearward angle relative to a longitudinal axis of the elastomeric friction member.

In some configurations, the elastomeric friction member comprises a projection configured to engage a cooperating recess in the collar to provide feedback to a user indicating proper connection of the frame and the cushion module.

In some configurations, the projection is a discrete structure extending around only a portion of a closed loop of the elastomeric friction member.

In some configurations, the projection extends around an entirety of a closed loop of the elastomeric friction member.

In some configurations, the projection is located on a rearward portion of the elastomeric friction member relative to a direction of assembly of the respiratory mask frame and the cushion module.

In some configurations, a respiratory mask comprises a frame configured to connect to headgear. The frame comprises a front wall at least partially defining a gas inlet opening. The frame further comprises a collar extending away from the front wall. The collar at least partially surrounds the gas inlet opening. A cushion module comprises a housing, a cushion and an elastomeric friction member. The cushion defines a face-contacting surface. The housing defines a connection opening. A portion of the housing defining the connection opening is embedded within the elastomeric friction member to couple the friction member to the housing. The housing is made of a material more rigid than the cushion and forms at least a portion of a breathing chamber of the respiratory mask. The friction member is configured to selectively connect the cushion module to the collar of the frame with a friction fit so that the flow of gas can be delivered to the breathing chamber through the gas inlet opening of the frame and the connection opening of the cushion module. The friction member engages an outer surface of the collar. An outer surface of the friction member is exposed when the cushion module is coupled to the frame.

In some configurations, the housing comprises a wall portion external of the friction member and extending between the friction member and the cushion.

In some configurations, the front wall of the frame further comprises a vent, and wherein the collar surrounds the vent in addition to the gas inlet.

In some configurations, a divider wall is located within an interior of the collar. The divider wall has a first end and a second end, each connected to the collar. The divider wall separates the vent and the gas inlet opening.

In some configurations, a surface of the divider wall adjacent the vent extends substantially in a direction of gas flow through the vent.

In some configurations, an elbow is supported by the frame and configured to deliver a flow of breathing gas through the gas inlet opening.

In some configurations, the collar and the divider wall cooperate to define a socket that receives the elbow.

In some configurations, the elbow has a swivel connection with the frame.

In some configurations, the collar extends rearwardly from the front wall of the frame to a rearward edge, wherein a rearward edge of the divider wall is positioned between the front wall of the frame and the rearward edge of the collar.

In some configurations, the housing of the cushion module further comprises a support flange, wherein the support flange defines the connection opening and extends within the friction member substantially in a direction of assembly of the cushion module to the frame.

In some configurations, the support flange comprises a plurality of apertures and wherein the friction member extends through each of the plurality of apertures.