Cushion member and method of manufacturing same

1. A cushion member for a patient interface device, the cushion member comprising:

a body portion comprising a first end and a second end disposed opposite the first end, the body portion defining a passage therethrough; and

a support portion extending from the second end into the passage, the support portion comprising a first portion and a second portion disposed on or in the first portion, wherein the support portion is movable from a first configuration to a second configuration responsive to a change in environment, wherein the first portion is made of a first material having a first coefficient of thermal expansion, and wherein the second portion is made of a second material having a second coefficient of thermal expansion different than the first coefficient of thermal expansion, wherein the support portion has an engaging portion structured to engage a face of a user; wherein the engaging portion faces away from an interior of the body portion; wherein, when the support portion is in the first configuration, the engaging portion is generally smooth; and wherein, when the support portion is in the second configuration, the engaging portion is roughened.

2. The cushion member according to claim 1 , wherein the first coefficient of thermal expansion is less than the second coefficient of thermal expansion; and wherein the second portion faces away from an interior of the body portion.

3. The cushion member according to claim 1 , wherein the difference between the first coefficient of thermal expansion and the second coefficient of thermal expansion is a first number; wherein the average of the first coefficient of thermal expansion and the second coefficient of thermal expansion is a second number; and wherein the first number divided by the second number is greater than 0.10.

4. The cushion member according to claim 1 , wherein the first portion has a nose bridge region, a first cheek region, and a second cheek region; wherein the support portion further comprises a third portion and a fourth portion each being made of a material having a coefficient of thermal expansion different than the first coefficient of thermal expansion; wherein the second portion is disposed on the first cheek region; wherein the third portion is disposed on the nose bridge region; and wherein the fourth portion is disposed on the second cheek region.

5. The cushion member according to claim 1 , wherein the support portion has an inner edge portion; wherein the cushion member has a first center of curvature when the support portion is in the first configuration and a first radius of curvature extending from the first center of curvature to the inner edge portion; wherein the cushion member has a second center of curvature when the support portion is in the second configuration and a second radius of curvature extending from the second center of curvature to the inner edge portion; wherein the second center of curvature is closer to the support portion than the first center of curvature; and wherein the second radius of curvature is less than the first radius of curvature.

6. The cushion member according to claim 1 , wherein the support portion is a sealing portion structured to engage a face of a user.

7. The cushion member according to claim 1 , wherein the second portion at least partially extends into the first portion.

8. The cushion member according to claim 1 , wherein the change in environment is selected from the group consisting of a change in temperature and a change in humidity.

9. The cushion member according to claim 1 , wherein, when the support portion moves from the first configuration to the second configuration, the support portion moves in a predetermined manner in order to be more curved.

10. A method of manufacturing a cushion member for a patient interface device, the method comprising the steps of:

providing a body portion having a first end and a second end disposed opposite the first end, the body portion defining a passage therethrough;

providing a first portion of a support portion, the first portion extending from the second end into the passage; and

providing a second portion of the support portion in or on the first portion, wherein the support portion is movable from a first configuration to a second configuration responsive to a change in environment, wherein the support portion changes shape when moving from the first configuration to the second configuration, wherein the first portion is made of a first material having a first coefficient of thermal expansion, and wherein the second portion is made of a second material having a second coefficient of thermal expansion different than the first coefficient of thermal expansion, wherein the support portion has an engaging portion structured to engage a face of a user; wherein the engaging portion faces away from an interior of the body portion; wherein, when the support portion is in the first configuration, the engaging portion is generally smooth; and wherein, when the support portion is in the second configuration, the engaging portion is roughened.

11. The method according to claim 10 , wherein the providing the first portion step further comprises printing the first portion with a three-dimensional printer.

12. The method according to claim 11 , wherein the providing the second portion step further comprises printing the second portion with the three-dimensional printer.

13. The method according to claim 10 , wherein the providing the second portion step further comprises overmolding the second portion on the first portion.