Forehead supports for facial masks

Abstract

A face mask assembly (FMA) for supplying breathable gas to a wearer. The face mask assembly (FMA) includes a mask frame including a support, a facial cushion attached to the mask frame, and a forehead support. The forehead support includes a forehead cushion assembly and an adjustment knob operatively coupled to the forehead cushion assembly. The adjustment knob is threadably engaged with the forehead cushion assembly such that turning movement of the adjustment knob causes the mask frame to be moved between retracted and extended positions with respect to the forehead cushion assembly.

1 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including:    (i) a receiver attached to the mask frame and defining an arcuately shaped channel;    (ii) an arcuately shaped elongate bar which is received within said channel of the receiver and configurable between retracted and extended positions; and    (iii) a forehead cushion assembly pivotally attached to a distal end of the bar.    
   
   
       2 . A face mask assembly as in  claim 1 , wherein the bar is a slider bar and is slidably received within said channel for movement between retracted and extended positions.  
   
   
       3 . A face mask assembly as in  claim 1 , wherein said forehead cushion assembly comprises a pair of cushion support plates.  
   
   
       4 . A face mask assembly as in  claim 3 , wherein the forehead cushion assembly comprises a central support pivotally connected to a distal end of the slider bar, and wherein said support plates extend outwardly from said central support.  
   
   
       5 . A face mask assembly as in  claim 4 , wherein the cushion support plates are connected to the central support so as to be substantially V-shaped relative to the slider bar.  
   
   
       6 . A face mask assembly as in  claim 4 , wherein the cushion support plates are connected to the central support so as to be substantially T-shaped relative to the slider bar.  
   
   
       7 . A face mask assembly as in  claim 3 , wherein the cushion support plates comprise apertures, and wherein the forehead cushion assembly comprises a pair of cushions having concave interior surfaces, and an attachment head protruding rearwardly therefrom which is inserted into and through a respective one of the apertures in the support plates so as to physically attach the cushions thereto.  
   
   
       8 . A face mask assembly as in  claim 1 , wherein the forehead cushion assembly comprises a convex or concave forehead cushion.  
   
   
       9 . A face mask assembly as in  claim 1 , wherein the receiver comprises a pair of opposed openings, and wherein said slider bar comprises a series of apertures spaced apart from one another in a general lengthwise direction of the slider bar and capable of respective alignment with the opposed openings of the receiver upon sliding movement of the slider bar between said retracted and extended positions thereof.  
   
   
       10 . A face mask assembly as in  claim 9 , wherein further comprising a position pin insertable through said opposed openings and a respective one of said apertures of the slider bar when said at least one aperture is aligned with said openings to positionally maintain the slider bar relative to the receiver.  
   
   
       11 . A face mask assembly as in  claim 1 , wherein the slider bar comprises a gear rack, and wherein the receiver comprises an adjustment knob having a pinion gear meshed with said gear rack, wherein turning movement of the adjustment knob causes the slider bar to be moved between the retracted and extended positions thereof.  
   
   
       12 . A face mask assembly as in  claim 11 , wherein the slider bar comprises a resilient detent button, and wherein the receiver comprises a series of longitudinally spaced apart position apertures, wherein the detent button is resiliently engageable with the position apertures as the slider bar is moved between the retracted and extended positions thereof.  
   
   
       13 . A face mask assembly as in  claim 11 , wherein the slider bar comprises an elongate slot, and wherein the adjustment knob comprises a head portion and a cylindrical post which connects the head portion to the pinion gear thereof, said cylindrical post being received within the elongate slot to allow for movement of the slider bar between the retracted and extended positions thereof.  
   
   
       14 . A face mask assembly as in  claim 13 , wherein the receiver comprises a circular bearing surface against which the knob head portion bears.  
   
   
       15 . A face mask assembly as in  claim 11 , wherein at least one of the gear rack and the pinion gear is a helical gear including helical teeth.  
   
   
       16 . A face mask assembly as in  claim 11 , wherein the receiver includes a raised position marker, and wherein the adjustment knob includes a series of spaced apart position apertures, wherein the raised position marker is resiliently engageable with the position apertures as the slider bar is moved between the retracted and extended positions thereof.  
   
   
       17 . A face mask assembly as in  claim 11 , wherein the gear rack and the pinion gear are configured to provide a variable rate of motion of the slider bar.  
   
   
       18 . A face mask assembly as in  claim 1 , wherein the slider bar comprises a resilient central tongue member, a push button and a fixed pawl carried by the tongue member, and wherein the receiver comprises an elongate slot through which the push button extends, and a series of ratchet teeth engageable with said pawl, wherein said pawl is disengaged from a respective one of said ratchet teeth upon pressing the push button so as to allow the slider bar to be moved slidably within the receiver between the retracted and extended positions thereof.  
   
   
       19 . A face mask assembly as in  claim 18 , wherein the slider bar comprises a said pawl on at least one side of said push button.  
   
   
       20 . A face mask assembly as in  claim 18 , comprising a pair of parallel edge slots which define said central resilient tongue member.  
   
   
       21 . A face mask assembly as in  claim 1 , comprising a pair of cushion pads, said cushion pads having a generally concave cushion flange, a cushion body portion supporting the cushion flange, and a pair of rearwardly protruding elongate foot pads.  
   
   
       22 . A face mask assembly as in  claim 21 , wherein the cushion body portion comprises an open channel, and wherein the forehead cushion assembly comprises a pair of cushion support plates having retaining clips which extend into said open channel and thereby retain the cushion pads to said support plates.  
   
   
       23 . A face mask assembly comprising a mask frame; a facial cushion attached to the mask frame; and a forehead support, and wherein said forehead support is capable of arcuate movement so as to be positionable within a predetermined target window.  
   
   
       24 . A face mask assembly according to  claim 23 , wherein the target window is defined by a plane that extends in the y and z directions, the y-direction extending vertically when the patient is sitting upright and the z-direction extending into the plane of the patient's face.  
   
   
       25 . A face mask assembly according to  claim 24 , wherein the target window is about 30-37 mm from the average patient's nasion region in the y-direction and about −22-28 mm from the average patient's nasion region in the z-direction.  
   
   
       26 . A face mask assembly according to  claim 24 , wherein upper and lower limits in the y-direction are determined on the basis of anthropometric data, and inner and outer limits in the z-direction are determined on the basis of anthropometric data and travel of a gusset portion of the cushion.  
   
   
       27 . A face mask assembly according to  claim 24 , wherein the forehead support is movable along an arcuate path having a hinge point located below the patient's eye in the upper cheek region, and having a radius of curvature of about 35-70 mm.  
   
   
       28 . A face mask assembly according to  claim 27 , wherein the hinge point is located about 35 mm below the average patient's nasion region in the y-direction and about 15 mm inwardly from the average patient's nasion region in the z-direction.  
   
   
       29 . A face mask assembly comprising a mask frame; a facial cushion attached to the mask frame; and a forehead support, and wherein said forehead support is capable of arcuate movement so as to be positionable at any point along the length of a predetermined target line, wherein: 
 the target line is defined by a substantially straight line that extends vertically when the patient is sitting upright, and    the target line is about 30 mm long and about 40 mm from an average patient's nasion region.    
   
   
       30 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including:    (i) a receiver attached to the mask frame including spaced-apart arcuately shaped channels that define an elongated central finger and outer guide rails;    (ii) an arcuately shaped elongate slider bar which is slidably received within said channels of the receiver for movements between retracted and extended positions, said slider bar being supported on said central finger and guided by said outer guide rails; and    (iii) a forehead cushion assembly attached to a distal end of the slider bar.    
   
   
       31 . A face mask assembly according to  claim 30 , wherein the slider bar comprises a gear rack, and wherein the receiver comprises an adjustment knob having a gear meshed with said gear rack, wherein turning movement of the adjustment knob causes the slider bar to be moved between the retracted and extended positions thereof.  
   
   
       32 . A face mask assembly according to  claim 31 , wherein the slider bar comprises an elongate slot, and wherein the adjustment knob comprises a head portion and a cylindrical post which connects the head portion to the gear thereof, said cylindrical post being received within the elongate slot to allow for movement of the slider bar between the retracted and extended positions thereof.  
   
   
       33 . A face mask assembly according to  claim 32 , wherein the head portion includes a plurality of grooves or finger grips to facilitate adjustment.  
   
   
       34 . A face mask assembly according to  claim 31 , wherein the receiver includes a bridge between the outer guide rails that provides a slot for retaining the adjustment knob.  
   
   
       35 . A face mask assembly according to  claim 30 , wherein the receiver includes a detent button that is resiliently engageable with a series of teeth provided on the slider bar as the slider bar is moved between the retracted and extended positions thereof.  
   
   
       36 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including a forehead cushion assembly and an adjustment knob operatively coupled to the forehead cushion assembly such that turning movement of the adjustment knob causes the forehead cushion assembly to be moved between retracted and extended positions.    
   
   
       37 . A face mask assembly according to  claim 36 , wherein said forehead support further includes: 
 a receiver attached to the mask frame and defining an arcuately shaped channel; and    an arcuately shaped elongate slider bar which is slidably received within said channel of the receiver for movements between retracted and extended positions, the forehead cushion assembly being attached to a distal end of said slider bar,    wherein the adjustment knob has a gear meshed with a gear rack provided to said slider bar such that turning movement of the adjustment knob causes the slider bar to be moved between the retracted and extended positions thereof.    
   
   
       38 . A face mask assembly according to  claim 37 , wherein the receiver includes a slot that retains the adjustment knob, the slot having a void positioned at a bottom end adjacent the mask frame for receiving the adjustment knob therein.  
   
   
       39 . A face mask assembly according to  claim 37 , wherein the receiver includes a slot that retains the adjustment knob, the slot having a void positioned at a top end adjacent the patient's forehead for receiving the adjustment knob therein.  
   
   
       40 . A face mask assembly according to  claim 36 , wherein the adjustment knob is operatively coupled to the forehead cushion assembly by a screw mechanism.  
   
   
       41 . A face mask assembly according to  claim 40 , wherein the adjustment knob includes internal threads that are meshed with a threaded shaft attached to the forehead cushion assembly such that turning movement of the adjustment knob causes the threaded shaft to be moved between retracted and extended positions.  
   
   
       42 . A face mask assembly according to  claim 41 , wherein the adjustment knob clips onto a support provided to the mask frame.  
   
   
       43 . A face mask assembly according to  claim 42 , wherein the support includes a prong that is positionable into a keyway of the threaded shaft to prevent movement.  
   
   
       44 . A face mask assembly according to  claim 41 , wherein the adjustment knob is ring-shaped.  
   
   
       45 . A face mask assembly according to  claim 40 , wherein the adjustment knob includes a threaded shaft that is meshed with an internally threaded tube attached to the forehead cushion assembly such that turning movement of the adjustment knob causes the internally threaded tube to be moved between retracted and extended positions.  
   
   
       46 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame including a support;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including a forehead cushion assembly and an adjustment knob operatively coupled to the forehead cushion assembly,    wherein the adjustment knob is threadably engaged with the forehead cushion assembly such that turning movement of the adjustment knob causes the mask frame to be moved between retracted and extended positions with respect to the forehead cushion assembly.    
   
   
       47 . A face mask assembly according to  claim 46 , wherein the adjustment knob includes a threaded shaft that is meshed with an internally threaded tube portion provided to the forehead cushion assembly.  
   
   
       48 . A face mask assembly according to  claim 47 , wherein the threaded shaft is integrally formed in one piece with the adjustment knob.  
   
   
       49 . A face mask assembly according to  claim 47 , wherein the threaded shaft is formed separately from the adjustment knob and permanently or semi-permanently assembled to the adjustment knob.  
   
   
       50 . A face mask assembly for supplying breathable gas to a wearer, the face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, the forehead support including a forehead cushion support movably mounted to the mask frame for movements between retracted and extended positions and a forehead cushion attached to the forehead cushion support,    wherein the forehead cushion support includes a first connector that engages a second connector provided by the forehead cushion, and the first and second connectors each include a connector side wall with one or more slots through the connector side wall that allows the first and second connectors to compress in use.    
   
   
       51 . A face mask assembly according to  claim 50 , wherein the second connector includes an attachment head.  
   
   
       52 . A face mask assembly according to  claim 50 , wherein the slots are provided in two rows with each row including two spaced-apart slots.  
   
   
       53 . A face mask assembly according to  claim 50 , wherein each slot has an elongated, generally rectangular configuration with a longitudinal axis that extends generally transverse to a longitudinal axis of the respective first and second connector.  
   
   
       54 . A face mask assembly according to  claim 50 , wherein each slot has a width of about 3 mm.  
   
   
       55 . A face mask assembly according to  claim 50 , wherein the one or more slots of the first connector are aligned with the one or more slots of the second connector.  
   
   
       56 . A forehead cushion support for a forehead support of a mask assembly, comprising: 
 forehead cushion support plates to support forehead cushions; and    a slider provided to the support plates,    wherein the slider includes a resilient tab to provide quick-release assembly to a mask frame.    
   
   
       57 . A forehead cushion support according to  claim 56 , wherein the slider extends generally transversely relative to the support plates.  
   
   
       58 . A forehead cushion support according to  claim 57 , wherein the slider includes male or female threads for forehead support depth adjustment.  
   
   
       59 . A forehead cushion support according to  claim 57 , wherein the slider includes relatively flat surfaces on opposing sides thereof to provide a keyed assembly with the mask frame.  
   
   
       60 . A forehead cushion support according to  claim 57 , wherein the slider includes recessed slots to provide indexed tactile feedback on adjustment position.  
   
   
       61 . A forehead cushion support according to  claim 57 , wherein the forehead cushion support plates include clip receptacles for engaging headgear clips associated with headgear straps.  
   
   
       62 . A forehead cushion support according to  claim 61 , wherein the clip receptacles are provided in front of attachment recesses that receive respective attachment heads of the forehead cushions.  
   
   
       63 . A forehead cushion support according to  claim 57 , wherein the forehead cushion support plates include slots for engaging headgear straps.  
   
   
       64 . A forehead cushion support according to  claim 63 , wherein the slots are open ended.  
   
   
       65 . A forehead cushion support according to  claim 57 , wherein the forehead cushion support plates and the slider are integrally molded in one piece.  
   
   
       66 . A forehead cushion support according to  claim 57 , wherein the slider includes one or more ribs to prevent rotation with respect to the mask frame.  
   
   
       67 . A forehead support for a mask assembly, comprising: 
 a support provided to a mask frame;    a forehead cushion support movably mounted to the support for generally linear movement between retracted and extended positions with respect to the support; and    an adjustment knob threadably engaged with the forehead cushion support such that turning movement of the adjustment knob causes the forehead cushion support to be moved between the retracted and extended positions.    
   
   
       68 . A forehead support according to  claim 67 , wherein the adjustment knob includes female threads that are meshed with a male threaded shaft provided to the forehead cushion support.  
   
   
       69 . A forehead support according to  claim 67 , wherein the adjustment knob includes male threaded shaft that is meshed with a female threaded shaft provided to the forehead cushion support.  
   
   
       70 . A forehead support according to  claim 69 , wherein the male threaded shaft is integrally formed in one piece with the adjustment knob.  
   
   
       71 . A forehead support according to  claim 69 , wherein the male threaded shaft is formed separately from the adjustment knob and permanently or semi-permanently assembled to the adjustment knob.  
   
   
       72 . A forehead support according to  claim 67 , wherein the adjustment knob is attached to the support with a snap-fit.  
   
   
       73 . A forehead support according to  claim 72 , wherein the support includes a quick-release button that releasably attaches the adjustment knob.  
   
   
       74 . A forehead support according to  claim 72 , wherein the adjustment knob includes a slotted head that can be deformed for disassembly.  
   
   
       75 . A forehead support according to  claim 67 , wherein the forehead cushion support includes a resilient tab to provide quick-release assembly to the support.  
   
   
       76 . A forehead support according to  claim 67 , wherein the support includes a key feature to prevent rotation of the forehead cushion support.  
   
   
       77 . A forehead support according to  claim 68 , further comprising a locking ring to retain the adjustment knob on the support.  
   
   
       78 . A forehead support according to  claim 68 , wherein the male threaded shaft is an insert removably mounted to the forehead cushion support.  
   
   
       79 . A forehead support according to  claim 67 , wherein the adjustment knob includes a gear that is meshed with a gear rack provided to the forehead cushion support.  
   
   
       80 . A forehead support according to  claim 79 , wherein the adjustment knob includes an adjustment head on both sides of the gear.  
   
   
       81 . A forehead support according to  claim 67 , wherein the adjustment knob includes a threaded shaft that is meshed in telescoping relation with an intermediate threaded tube provided between the adjustment knob and the forehead cushion support.  
   
   
       82 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including:    (i) a receiver attached to the mask frame and defining an arcuately shaped channel;    (ii) an arcuately shaped elongate slider bar which is slidably received within said channel of the receiver for movement between retracted and extended positions; and    (iii) a forehead cushion assembly rigidly connected to a distal end of the slider bar.    
   
   
       83 . A face mask assembly according to  claim 46 , wherein the adjustment knob includes internal threads that are meshed with a threaded shaft such that turning movement of the adjustment knob causes the threaded shaft to extend or retract relative to the adjustment knob which causes adjustable movement of the forehead cushion assembly.  
   
   
       84 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame; and    a forehead support, said forehead support including a forehead cushion assembly and an adjustment knob operatively coupled to the forehead cushion assembly such that turning movement of the adjustment knob causes the forehead cushion assembly to be moved between retracted and extended positions,    wherein the adjustment knob is operatively coupled to the forehead cushion assembly by a screw mechanism, the adjustment knob including internal threads that are meshed with a threaded shaft such that turning movement of the adjustment knob causes adjustable movement of the forehead cushion assembly.    
   
   
       85 . A face mask assembly according to  claim 84 , wherein turning movement of the adjustment knob causes the threaded shaft to extend or retract relative to the adjustment knob.  
   
   
       86 . A face mask assembly according to  claim 84 , wherein the adjustment knob is ring-shaped.  
   
   
       87 . A facial mask for continuous positive airway pressure treatment of sleep disordered breathing, comprising: 
 a frame defining a cavity to receive a nose and mouth of a patient;    a soft cushion attached to the mask frame and adapted to form a seal against the face of the patient in use;    a headgear assembly comprising an arrangement of straps adapted to hold the frame and cushion in position on the patient's face; and    a forehead support structure adapted to be adjusted between an extended position and a retracted position, said forehead support comprising: 
 a curved link,  
 an adjustment knob constructed and arranged to be turned manually in both clockwise and counterclockwise directions so as to adjust said curved link between said extended position and said retracted position,  
 a forehead cushion support plate carrying at least one forehead cushion for placement against a wearer's forehead region, said forehead cushion support plate pivotally connected to said curved link so that pivoting movement of the forehead cushion support plate allows the at least one forehead cushion to be positioned flat against the wearer's forehead region through the range of adjustment between said extended position and said retracted position.  
   
   
   
       88 . A face mask assembly for supplying breathable gas to a wearer, said face mask assembly comprising: 
 a mask frame;    a facial cushion attached to the mask frame;    a forehead support, said forehead support including: 
 a support provided to the mask frame;  
 a forehead cushion support movably mounted to the support for movement between retracted and extended positions;  
 a forehead cushion attached to the forehead cushion support; and  
 an adjustment knob operatively coupled to the forehead cushion support such that turning movement of the adjustment knob causes the forehead cushion support to be moved between the retracted and extended positions; and  
   an elbow connector coupled to the mask,    wherein the mask frame includes connection structures adapted to connect to headgear clips associated with headgear, and    wherein the forehead cushion support includes a forehead cushion support plate to support the forehead cushion, the forehead cushion support plate pivotally mounted for pivoting movement.    
   
   
       89 . A face mask assembly according to  claim 88 , further comprising a screw mechanism to allow relative movement between the mask frame and the forehead support.