Fabric cushion member

A method of manufacturing a cushion member for a patient interface device, the cushion member comprising a sealing portion and a base portion, the base portion being structured to be coupled to a gas delivery conduit, the sealing portion comprising a flap portion, the method comprising the steps of:

• mechanically bonding a first layer of the flap portion to a second layer of the flap portion, the first layer being structured to engage a face of a patient and being made of a fabric material, the second layer being made of a material selected from the group consisting of a monomer, a polymer, and a mixture of a monomer and a polymer;
• and
• bonding the base portion to the second layer, wherein the flap portion has an outer edge and an inner edge, wherein the base portion comprises a bonding layer chemically bonded to a first side of the second layer to form a lap-joint, wherein a second side of the second layer at the lap-joint is mechanically bonded to the first layer such that the second layer is disposed between the first layer and the bonding layer at the lap-joint, and wherein the bonding layer is disposed between the outer edge and the inner edge,
• wherein the flap portion further has a nose bridge portion, a pair of opposing nasal transition portions each extending from the nose bridge portion, and a body portion connecting the nasal transition portions to one another, wherein the bonding layer extends inwardly from the outer edge of the nose bridge portion a first distance, and wherein the bonding layer extends inwardly from the outer edge of the body portion a second distance greater than the first distance such that the lap-joint has a first length proximate the nose bridge portion and a second length proximate the body portion with the second length being greater than the first length.

A patient interface device comprising:

• (a) a frame member;
• (b) a strap member coupled to the frame member;
• and
• (c) a cushion member coupled to the frame member, the cushion member comprising:
• (1) a sealing portion comprising a flap portion including a first layer and a second layer mechanically bonded to the first layer, the first layer being structured to engage a face of a patient and being made of a fabric material, the second layer being made of a material selected from the group consisting of a monomer, a polymer, and a mixture of a monomer and a polymer;
• and
• (2) a base portion bonded to the second layer, the base portion being structured to be coupled to a gas delivery conduit, wherein the flap portion has an outer edge and an inner edge, wherein the base portion comprises a bonding layer chemically bonded to a first side of the second layer to form a lap-joint, wherein a second side of the second layer at the lap-joint is mechanically bonded to the first layer such that the second layer is disposed between the first layer and the bonding layer at the lap-joint, and wherein the bonding layer is disposed between the outer edge and the inner edge,
• wherein the flap portion further has a nose bridge portion, a pair of opposing nasal transition portions each extending from the nose bridge portion, and a body portion connecting the nasal transition portions to one another, wherein the bonding layer extends inwardly from the outer edge of the nose bridge portion a first distance, and wherein the bonding layer extends inwardly from the outer edge of the body portion a second distance greater than the first distance such that the lap-joint has a first length proximate the nose bridge portion and a second length proximate the body portion with the second length being greater than the first length.