IP Library Granted Patent US 12,350,430
Granted Patent B2
US 12,350,430 · App. 18/509,922 · Granted Jul 8, 2025

Respiratory mask with good sealing and comfort

Inventor: David Luo (New York, NY)
Assignee: DCSTAR INC
A61M16/0622A61M2207/10
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,350,430
App. No.
18/509,922
Granted
Jul 8, 2025
Kind
B2
Abstract

A comfortable, well-sealing respiratory mask with an annular comfort layer. The respiratory mask includes a rigid component, an elastic component, and an annular comfort layer. The rigid component is equipped with a gas delivery interface and an annular interface; the elastic component is connected to the rigid component and features a first accommodation area designed to house the user's mouth and nose or only the nose. On one side of the elastic component far away from the rigid component, there is at least one pressing part designed to seal at least a portion of the user's nose; the annular comfort layer has a second accommodation area that communicates with the first accommodation area, covering at least part of the pressing part and jointly forming a sealed surface with the elastic component.

Claims (89)

1. A respiratory mask configured to enclose a user's nose and a user's mouth by forming a sealing area between a lower lip and a nasal bridge, or to enclose only the user's nose by forming a sealing area between an upper lip area and the nasal bridge area, wherein the respiratory mask is configured to supply pressurized respiratory gas to an airway of the user, the respiratory mask comprising:

a rigid component comprising:

at least one gas delivery interface at a side configured to be farthest away from a face of the user, and

an annular interface at a nearest side of the rigid component configured to be closest to the face of the user configured to form a joint part along an outer edge of the annular interface;

an elastic component including:

a first accommodation area configured to house the user's mouth and the user's nose or only the nose, the first accommodation area communicating with an inner cavity of the rigid component, and the first accommodation area having a side of the elastic component that is closest to the rigid component fixedly connected to the joint part,

a pressing part configured to seal at least a portion of the user's nose on a side of the elastic component that faces away from the rigid component; and

an annular comfort layer configured to seal at least part of the face of the user when in use, the annular comfort layer including:

a second accommodation area configured to house the user's mouth and the user's nose or only the nose, the second accommodation area being connected to the first accommodation area,

wherein the annular comfort layer is fixedly connected to the side of the elastic component facing away from the rigid component and covers at least part of the pressing part and is configured to form a sealed surface that contacts the face of the user together with the elastic component;

wherein a portion of the elastic component is configured to contact the face of the user within the interior of an inner edge of the annular comfort layer,

wherein the annular comfort layer is made of foam material;

wherein the annular comfort layer is configured to include a density at or between 10 to 200 kg/m 3 ; and

wherein the annular comfort layer is configured to include a ratio of a width to a height at or between 0.1 to 30.

2. The respiratory mask according to claim 1 , wherein

the rigid component is made of plastic material,

the elastic component is made of silicone, rubber, thermoplastic elastomer, or silicone resin material, and

the annular comfort layer is made of polyurethane, low-density polyether, or ethylene-vinyl acetate material.

3. The respiratory mask according to claim 2 , wherein a cross-sectional shape of the annular comfort layer is triangular, quadrilateral, pentagonal, or hexagonal.

4. The respiratory mask according to claim 3 , wherein a perimeter of an inner edge of the annular comfort layer is greater than or equal to a perimeter of an inner edge on a side of the elastic component adjacent to the pressing part.

5. A respiratory mask configured to enclose a user's nose and a user's mouth by forming a sealing area between a lower lip area and a nasal bridge area, or to enclose only the user's nose by forming a sealing area between an upper lip area and the nasal bridge area, wherein the respiratory mask is configured to supply pressurized respiratory gas to an airway of the user, the respiratory mask comprising:

a rigid component comprising:

at least one gas delivery interface at a farthest side configured to be away from a face of the user, and

an annular interface at a nearest side of the rigid component configured to be closest to the face of the user configured to form a joint part along an outer edge of the annular interface;

an elastic component including:

a first accommodation area configured to house the user's mouth and the user's nose or only the nose, the first accommodation area communicating with an inner cavity of the rigid component, and the first accommodation area having a side of the elastic component that is closest to the rigid component fixedly connected to the joint part,

a pressing part configured to seal at least a portion of the user's nose on a side of the elastic component that faces away from the rigid component, and

an annular comfort layer configured to seal at least part of the face of the user when in use, the annular comfort layer including:

a second accommodation area configured to house the user's mouth and the user's nose or only the nose, the second accommodation area being connected to the first accommodation area,

wherein the annular comfort layer is fixedly connected to the side of the elastic component facing away from the rigid component and covers at least part of the pressing part, and is configured to form a sealed surface that contacts the face of the user together with the elastic component within the interior of an inner edge of the annular comfort layer;

wherein the annular comfort layer is made of foam material;

wherein the annular comfort layer includes a first surface configured to be in contact with the face of the user and a second surface connected to the elastic component, with an angle α between the first surface and the second surface being at or between 0 to 80 degrees;

wherein the annular comfort layer is configured to include a density at or between 10 to 200 kg/m 3 ; and

wherein the annular comfort layer is configured to include a ratio of a width to a height at or between 0.1 to 30.

6. The respiratory mask according to claim 5 , wherein

the elastic component is made of silicone material,

the annular comfort layer is made of polyurethane, low-density polyether, or ethylene-vinyl acetate material,

a perimeter of an inner edge of the annular comfort layer is greater than or equal to a perimeter of an inner edge on a side of the elastic component adjacent to the pressing part, and

a shape of the second surface of the annular comfort layer is adapted to a shape on the side adjacent to the pressing part of the elastic component.

7. The respiratory mask according to claim 6 , wherein a height of the annular comfort layer is at or between 1 to 30 mm.

8. The respiratory mask according to claim 5 , wherein the elastic component and the annular comfort layer are connected through molding, hot pressing, welding, foaming, or adhesive.

9. A respiratory mask configured to enclose a user's nose and mouth by forming a sealing area between a lower lip area and a nasal bridge area, or to enclose only the user's nose by forming a sealing area between an upper lip area and the nasal bridge area, wherein the respiratory mask is configured to supply pressurized respiratory gas to an airway of the user, the respiratory mask comprising:

a rigid component comprising:

at least one gas delivery interface at a side configured to be farthest away from a face of the user, and

an annular interface at a nearest side of the rigid component configured to be closest to the face of the user configured to form a joint part along an outer edge of the annular interface;

an elastic component, configured to adjust a distance between the rigid component and the face of the user, the elastic component including:

a first accommodation area configured to house the user's mouth and the user's nose or only the nose, the first accommodation area communicating with an inner cavity of the rigid component, and the first accommodation area having:

a side of the elastic component closest to the rigid component fixedly connected to the joint part, and

a side of the elastic component facing away from the rigid component having a non-thin area and at least one thin area, with a wall thickness of the thin area being at or between 0.2 to 2 mm;

an annular comfort layer configured to seal at least part of the face of the user when in use, a portion of the elastic component being configured to contact the face of the user within the interior of an inner edge of the annular comfort layer, the annular comfort layer including:

a second accommodation area configured to house the user's mouth and the user's nose or only the nose, the second accommodation area being connected to the first accommodation area,

wherein the annular comfort layer is fixedly connected to the side of the elastic component that faces away from the rigid component and covers at least part of the elastic component;

wherein the annular comfort layer made of at least one absorbent material;

wherein the annular comfort layer includes a first surface that is configured to contact the face of the user and a second surface that connects to the elastic component;

wherein the distance variation between the first surface of the annular comfort layer and the rigid component is to yield at least two different values when applying a same force in a constant direction to different positions of the annular comfort layer;

wherein the annular comfort layer is configured to include a density at or between 10 to 200 kg/m 3 ; and

wherein the annular comfort layer is configured to include a ratio of a width to a height at or between 0.1 to 30.

10. The respiratory mask according to claim 9 , wherein

both the thin area and the non-thin area are configured to be at least partially in contact with the face of the user, and

the thickness of at least one portion of the thin area configured to contact the face of the user is 7%-60% of a thickness of a portion of the non-thin area configured to contact the face of the user.

11. The respiratory mask according to claim 10 , wherein the thin area corresponds to at least one of the user's nose or the user's mouth.

12. The respiratory mask according to claim 9 , wherein

the elastic component is made of non-breathable material, and

the annular comfort layer is made of foam material, textile material, or a composite material of foam and textile, the foam material being polyurethane.

13. A respiratory mask configured to enclose a user's nose and a user's mouth by forming a sealing area between a lower lip area and a nasal bridge area, or to enclose only the user's nose by forming a sealing area between an upper lip area and the nasal bridge area, wherein the respiratory mask is configured to supply pressurized respiratory gas to an airway of the user, the respiratory mask comprising:

a rigid component comprising:

at least one gas delivery interface at a side configured to be farthest away from a face of the user, and

an annular interface at a nearest side of the rigid component configured to be closest to the face of the user configured to form a joint part along an outer edge of the annular interface;

an elastic component, configured to adjust a distance between the rigid component and the face of the user, the elastic component including:

a first accommodation area configured to house the user's mouth and the user's nose, the first accommodation area communicating with an inner cavity of the rigid component, the first accommodation area having:

a side of the elastic component closest to the rigid component fixedly connected to the joint part, and

a side of the elastic component facing away from the rigid component having a non-thin area and at least one thin area, with a wall thickness of the thin area being at or between 0.2 to 2 mm; and

an annular comfort layer configured to seal at least part of the user's face when in use, the annular comfort layer including:

a second accommodation area configured to house the user's mouth and the user's nose, the second accommodation area being connected to the first accommodation area,

wherein the annular comfort layer is fixedly connected to the side of the elastic component facing away from the rigid component and covers at least part of the elastic component to form a sealed surface that contacts the face of the user together with the elastic component;

wherein the annular comfort layer is made of at least one absorbent material;

wherein the annular comfort layer includes a first surface that is configured to contact the face of the user and a second surface that is configured to connect to the elastic component, and

wherein a portion of the elastic component is configured to extend closer to the patient's face than the annular comfort layer.

14. The respiratory mask according to claim 13 , wherein

an angle α between the first surface and the second surface is at or between 0 to 80°, and

the thin area corresponds to at least one of the user's nose or the user's mouth.

15. The respiratory mask according to claim 13 , wherein

the elastic component is made of silicone, rubber, thermoplastic elastomer, or silicone resin material, and

the absorbent material is foam material, textile material, or a composite of foam and textile materials.

16. The respiratory mask according to claim 13 , wherein the elastic component and the annular comfort layer are connected in a non-removable manner.

17. The respiratory mask according to claim 13 , wherein the elastic component is made of silicone material,

the annular comfort layer is made of textile material, which is nylon, spandex, or polyester; and

a perimeter of an inner edge of the annular comfort layer is greater than or equal to a perimeter of an inner edge on a side of the elastic component adjacent to a pressing part configured to seal at least a portion of the user's nose thereto.

18. The respiratory mask according to claim 13 , wherein a height of the annular comfort layer is uniform.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 15, 2023
From: LUO, DAVID
To: DCSTAR INC
Reel/Frame 065576/0192 →
Continuity (1)
Related Publication 20250152887A1 · May 15, 2025
References Cited (8)
US 20090014007A1 · Brambilla · 2009 [cited by examiner]
US 20100326445A1 · Veliss · 2010 [cited by examiner]
US 20140251338A1 · Asvadi · 2014 [cited by examiner]
US 20150246198A1 · Bearne · 2015 [cited by examiner]
US 20170128689A1 · Law · 2017 [cited by examiner]
US 20200016358A1 · Bornholdt · 2020 [cited by examiner]
US 20230302245A1 · Eves · 2023 [cited by examiner]
WO WO2014117227A9 · 2014 [cited by examiner]