Cushion for patient interface device, breathing mask with cushion, and method and apparatus for same

A cushion for a patient breathing mask interface, comprising:

• a first fibrous mask side layer;
• a second slip-resistant fibrous facial side layer, superposed on the first layer;
• a third, fluid barrier layer interposed between the first and second layers, the layers having a generally polygonal shape;
• and
• wherein the layers are integrally bonded together into a laminar composite defining a form-fitting, generally self-adjusting three-dimensional body having a J-shaped cross section including an inboard curl defining a patient-engaging portion and an interface-engaging portion, the curl opening into a dampening chamber juxtaposed with one or more of the patient's airways and communicating with a pressurized source of a dampening medium delivered to the chamber, the laminar composite is stretch-bonded together into a substantially shape-retaining and dimensionally-stable construction.

A method of making a cushion blank for a patient breathing mask interface, the method comprising the steps of:

• (a) providing a mold set having a first platen with a generally annular protruding wall including inner and outer surfaces terminating in a common lip and a juxtaposed second platen including a corresponding generally annular groove, the lip and groove together confining a mold space as the platens are moved relative to one another;
• (b) providing a stretchable laminar composite sheet having a fibrous surface and a fluid impermeable barrier;
• (c) providing a means for retaining the sheet of (b) in fixed position between the lip and groove;
• (d) relatively moving the platens and entrapping the sheet in tension within the mold space as the mold set is closed;
• and
• (e) opening the mold set and removing a three-dimensional form-fitting, generally self-adjusting cushion blank having a curled lip, the composite sheet of the blank exhibiting a Taber Stiffness value between about 4 to about 10 Taber Stiffness Units.

An interface for a Continuous Positive Air Pressure mask having a contoured nose portion, the interface comprising:

• (a) a bracket mounted to the mask adjacent the nose portion;
• (b) a cushion supported by a flange articulating with the bracket, the cushion including (i) a first fibrous mask side layer, (ii) a second slip-resistant fibrous facial side layer, superposed on the first layer, and (iii) a third, elastomeric sealing layer interposed between the first and second layers, the layers having an open generally triangular shape;
• and
• (c) wherein the layers are stretch-bonded together into an integral laminar composite defining a form-fitting, generally self-adjusting open, dimensionally-constant triangular shaped body containing an air chamber juxtaposed with the patient's nasal airway and communicating with a pressurized air source, the body further having a J-shaped cross section including an inboard curl that engages the bridge of the patient's nose and facial curves, the body also including a contiguous outboard wall that terminates in a mask engaging rim, the laminar composite is stretch-bonded together into a substantially shape-retaining construction.