Cushion, method of and apparatus for molding a cushion for a respiratory mask

1. A method of manufacturing a cushion for a respiratory mask, comprising:

providing a mold, the mold comprising at least two mold halves and at least one core, the at least one core being C-shaped;

closing the mold around the core;

injecting a first material into the mold and around the at least one core to enclose the core by the first material and form the cushion as a one-component structure with a central through hole;

opening the mold; and

removing the core from within the cushion through a single orifice; and

sealing the orifice after the core is removed from within the cushion;

wherein:

removal of the core from within the cushion creates at least one cavity completely surrounded by the cushion but for the single orifice through which the core is removed;

a cross section along a central axis of the central through hole immediately after removal of the core includes an uninterrupted perimeter around the at least one cavity;

the single orifice provides the only fluid communication between the at least one cavity and an environment external to the cushion; and

the at least one cavity is defined solely by the first material of the surrounding cushion.

2. The method according to claim 1 , wherein removing the core from the cushion comprises displacing the core together with the cushion relative to the mold halves.

3. The method according to claim 1 , further comprising sealing the cavity by one or more of injecting the first material into the orifice, gluing an insert into the orifice, gluing a patch over the orifice, and overmolding the cushion including the orifice.

4. The method according to claim 1 , further comprising filling the cavity with a second material prior to sealing the cavity.

5. The method according to claim 4 , wherein the second material comprises at least one foam, gel, liquid, gas, or beads, or a combination thereof.

6. The method of claim 4 , wherein the second material is silicone.

7. The method according to claim 1 , further comprising adjusting rigidity of the cushion by varying thickness and/or structure of a cushion wall along a cross section and/or circumference of the cushion wall.

8. The method according to claim 1 , further comprising adjusting rigidity of the cushion by providing ribs and/or grooves on an inner surface of the cushion or within the inner surface of the cushion, the inner surface of the cushion comprising inner cavity walls.

9. The method according to claim 1 , further comprising creating the cushion with varying thickness by varying a thickness of the core.

10. The method according to claim 9 , further comprising creating protruding structures on the cushion.

11. The method according to claim 10 , wherein the protruding structures are created by providing complementary structures on a surface of the core.

12. The method according to claim 11 , wherein the complementary structures are grooves and/or ribs.

13. The method according to claim 1 , further comprising creating two or more horizontal or longitudinal cavities which are separated by one or more horizontal walls or membranes.

14. The method according to claim 13 , further comprising forming two or more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

15. The method of manufacturing a cushion for a respiratory mask according to claim 1 , further comprising:

stretching the cushion to allow the core to be removed from the cushion through the orifice; and

returning the cushion to a predetermined molded shape after the core is removed from the cushion.

16. The method according to claim 1 , further comprising forming two or more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

17. A method for manufacturing a cushion usable in a respiratory mask, the method comprising:

injecting a first elastomeric material into a mold, the mold comprising at least two mold segments and at least one core enclosed within a chamber defined by the mold segments, to form a one-component cushion body within the mold, the cushion body forming around and substantially enclosing the at least one core, the cushion body having at least one substantially enclosed cavity formed by the core and an opening sized to fit around a patient's nose, the at least one cavity being substantially surrounded by the first material so that a cross section of the one-component cushion body along a central axis of the opening includes an uninterrupted perimeter of the first elastomeric material around the at least one cavity prior to removal of the at least one core from the cushion body; and

removing the cushion body from the at least one core such that only a single orifice through which the cushion body was removed provides fluid communication between the at least one cavity and an environment external to the cushion body.

18. The method according to claim 17 , further comprising sealing the cavity.

19. The method according to claim 18 , further comprising: filling the at least one cavity with a second material prior to sealing the cavity.

20. The method according to claim 17 , further comprising forming the orifice to be continuous with the cushion body, deformable, and around a portion of the core.

21. The method according to claim 20 , wherein a width of the orifice is approximately half a maximum width of the core.

22. The method according to claim 20 , wherein a length of the orifice is between approximately one-fourth and one-eighth a maximum height of the core.

23. The method according to claim 20 , further comprising attaching the at least one core to a handling member that is moveable with respect to at least one of the mold segments.

24. The method according to claim 23 , further comprising placing the handling member to extent through the orifice during and withdrawing the at least one core from the cushion body through the orifice during demolding using the handling member.

25. The method according to claim 17 , further comprising:

creating protrusions and/or indentations on inner surfaces of walls bounding the at least one cavity with the core; and

locating the protrusions and/or indentations to locally vary a rigidity of the cushion body.

26. The method according to claim 17 , further comprising:

creating variations in thickness in the cushion with variations in thickness of the core.

27. The method of manufacturing a cushion for a respiratory mask according to claim 17 , further comprising:

stretching the cushion body to allow the core to be removed from the cushion body through the orifice; and

returning the cushion body to a predetermined molded shape after the core is removed from the cushion body.

28. A cushion usable in a respiratory mask, comprising:

a cushion body formed from a first elastomeric material around a central through hole; and

at least one enclosed cavity inside the cushion body, wherein a cross section along a central axis of the central through hole includes an uninterrupted and continuous perimeter of the first elastomeric material around the cavity;

wherein only a single fillable orifice provides fluid communication between the at least one enclosed cavity and an environment external to the cushion body.

29. The cushion according to claim 28 , wherein the cushion comprises two or more horizontal or longitudinal cavities which are separated by one or more horizontal walls or membranes.

30. The cushion according to claim 29 , and wherein the cushion also comprises two or more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

31. The cushion according to claim 28 , wherein a ratio between a width of the orifice and a width of the cavity is in the range from about 1/1.5 to 1/2.5, and/or wherein the ratio between a length of the orifice and a height of the cavity lies in a range from about 1/5 to 1/7.

32. The cushion according to claim 31 , wherein the ratio between the width of the cavity and the width of the orifice is about 1/2.

33. The cushion according to claim 31 , wherein the ratio between the length of the orifice and the height of the cavity is about 1/6.

34. The cushion according to claim 28 , wherein the cushion comprises only one of the enclosed cavity and the enclosed cavity is a C-shaped cavity extending only along a part of a circumference of the cushion.

35. The cushion according to claim 28 , wherein the orifice is deformable.

36. The cushion according to claim 28 , wherein:

the cushion body has protrusions and/or indentations on at least one inner wall bounding the at least one cavity; and

the protrusions and/or indentations locally vary a rigidity of the cushion body.

37. The cushion according to claim 28 , wherein:

the cushion body has varying thickness to vary rigidity of the cushion body at different locations.

38. The cushion for a respiratory mask according to claim 28 ,

wherein:

the cushion body is configured to stretch at least in a region containing the orifice; and

the cushion body is configured to resiliently return to a predetermined molded shape after the region containing the orifice is stretched.

39. The cushion according to claim 28 , wherein the cushion comprises at least one C-shaped cavity extending only along a part of a circumference of the cushion.

40. The cushion according to claim 28 , wherein the cushion comprises two or more vertical or transverse cavities or pockets which are separated by walls or membranes extending substantially vertically.

41. A cushion for a respiratory mask comprising:

a cushion body comprising a first material, the cushion body including a central through hole that is sized to fit over and around a patient's nose; and

an enclosed cavity within the cushion body;

wherein:

the cushion body is a continuous, hollow structure but for a single orifice;

a cross section of the cushion body along a central axis of the central through hole comprises an uninterrupted perimeter of the first material around the enclosed cavity; and

the enclosed cavity is substantially C-shaped.