# US 11,110,241 B2 · Fabric cushion member > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,110,241 B2 - Document ID: US11110241B2 - Status: Granted - Kind: B2 - Application number: 16/084,577 - Filed: 2017-03-08 - Published: 2019-03-07 - Granted: 2021-09-07 - Earliest claimed: 2016-03-14 - Assignees: Koninklijke Philips N.V. - Applicants: Koninklijke Philips N.V. - Inventors: Harold Allen Lockhart; Derrick Blake Andrews - Web page: https://patentgrep.com/patent/US11110241B2 ## CPC - A61M 16/0622: {having an underlying cushion} - A61M 16/06: Respiratory or anaesthetic masks - A61M 16/0616: {with face sealing means comprising a flap or membrane projecting inwards, such that sealing increases with increasing inhalation gas pressure} - A61M 16/0683: {Holding devices therefor} - A61M 2205/0216: Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking - A61M 2205/0238: the material being a coating or protective layer - A61M 2207/00: Methods of manufacture, assembly or production - A61M: DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY (introducing media into or onto the bodies of animals A61D7/00; means for inserting tampons A61F13/26; devices for administering food or medicines orally A61J; containers for collecting, storing or administering blood or medical fluids A61J1/05); DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY (surgery A61B; chemical aspects of surgical articles A61L); DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR {(Electrotherapy, e.g. producing anaesthesia by the use of alternating or intermittent currents A61N1/36021)} ## Abstract A cushion member (100, 200) for a patient interface device (4) that includes a sealing portion (110, 210) having a flap portion (111, 211) including a first layer (116, 216) and a second layer (118, 218) mechanically bonded to the first layer. The first layer is structured to engage a face of a patient and is made of a fabric material. The second layer is made of a material selected from the group consisting of a monomer, a polymer, and a mixture of a monomer and a polymer. A base portion (170, 270) is bonded to the second layer. The base portion is structured to be coupled to a gas delivery conduit (8). ## Claims ### Claim 1 A cushion member for a patient interface device, the cushion member comprising: 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 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. ### Claim 2 (depends on 1) The cushion member according to claim 1, wherein the bonding layer extends inwardly from the outer edge of the nasal transition portions a third distance greater than the first distance and the second distance. ### Claim 3 (depends on 1) The cushion member according to claim 1, wherein the second layer comprises a first portion and a second portion extending from the first portion, wherein the first portion is chemically bonded to the bonding layer, wherein the second portion is not chemically bonded to the bonding layer, and wherein the second portion is flat. ### Claim 4 (depends on 1) The cushion member according to claim 1, wherein the sealing portion further comprises a bead chemically bonded to the base portion and the second layer. ### Claim 5 (depends on 4) The cushion member according to claim 4, wherein the flap portion comprises an outer edge, and wherein the bead overlays the outer edge. ### Claim 6 (depends on 1) The cushion member according to claim 1, wherein the flap portion comprises a first bonding portion and a second bonding portion disposed opposite the first bonding portion, wherein the sealing portion further comprises a second flap portion made of a material selected from the group consisting of a monomer, a polymer, and a mixture of a monomer and a polymer, wherein the second flap portion is mechanically bonded to the first layer of the first bonding portion and chemically bonded to the second layer of the first bonding portion, and wherein the second flap portion is mechanically bonded to the first layer of the second bonding portion and chemically bonded to the second layer of the second bonding portion. ### Claim 7 (depends on 1) The cushion member according to claim 1, wherein the flap portion is not in a state of tension. ### Claim 8 (depends on 1) The cushion member according to claim 1, wherein the first layer has a density of between 100 and 350 grams per square meter. ### Claim 9 (depends on 1) The cushion member according to claim 1, wherein the second layer has a thickness of between 0.002 and 0.02 inches. ### Claim 10 (depends on 1) The cushion member according to claim 1, wherein the second layer partially extends into the first layer. ### Claim 11 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. ### Claim 12 (depends on 11) The method according to claim 11, further comprising the step of bonding a bead to the base portion and the second layer. ### Claim 13 (depends on 11) The method according to claim 11, wherein the flap portion comprises a first bonding portion and a second bonding portion disposed opposite the first bonding portion, wherein the sealing portion further comprises a second flap portion made of a material selected from the group consisting of a monomer, a polymer, and a mixture of a monomer and a polymer, and wherein the method further comprises the steps of: mechanically bonding the second flap portion to the first layer of the first bonding portion and the first layer of the second bonding portion; and chemically bonding the second flap portion to the second layer of the first bonding portion and the second layer of the second bonding portion. ### Claim 14 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.