Patient interface structure and method/tool for manufacturing same

Abstract

Component of a patient interface, particularly a cushion, comprising a first part and a second part, wherein the second part is made of a foamed material which is foamed-on the first part. A Method and tool for manufacturing a component of a patient interface, particularly a cushion, comprising the steps molding a first part of the component and foaming a second part on the first part.

1 . Method of manufacturing a component of a patient interface, particularly a cushion, comprising the steps:
 molding a first part of the component and foaming a second part on the first part.   
   
   
       2 . Method according to  claim 1 , further comprising the steps:
 handling the first part, the second part and/or the component, wherein the first part constitutes and/or comprises the handling structure.   
   
   
       3 . Method of producing a component of a patient interface, particularly according to  claim 1 , comprising the following steps:
 a) providing a molding tool having a first mold part and a second mold part which are adapted to define a first mold cavity there between;   b) providing, preferably injecting, a first material into the first molding tool in order to provide a first part of the component;   c) removing the first part from the first cavity;   d) providing a third mold and a fourth mold part adapted to define a second mold cavity between them;   e) inserting the first part into the second cavity;   f) providing a second foamed material into the second mold cavity in order to provide a foamed second part integral with the first part.   
   
   
       4 . Method according to  claim 1 , wherein the hardness of the first part is higher than the hardness of the second part. 
   
   
       5 . Method according to  claim 1 , wherein first part removed from the first mold part and the second mold part and inserted into a third mold part and/or a fourth mold part, thereby defining, preferably in combination with the third mold part and/or the fourth mold part, a second cavity for foaming on a second part on the first part. 
   
   
       6 . Method according to  claim 1 , wherein a third mold part and/or a fourth mold part are provided having at least one pressure rim structure and wherein the pressure rim structure(s) is/are sealingly pressed against the first part for defining a merging surface on the first part and/or for sealingly defining a second cavity. 
   
   
       7 . Method according to  claim 1 , wherein a first mold part and/or a second mold part are provided having at least one negative pressure rim structure and wherein the molded first part comprises at least one pressure rim structure molded by the negative pressure rim structure(s) of the first and/or second part. 
   
   
       8 . Method according to  claim 1 , wherein mold parts are provided having a sealing means, preferably a silicone sealing lip and/or silicone sealing ring defining at least one pressure rim which is/are sealingly pressed against the first part for defining a merging surface on the first part and/or for sealingly defining a second cavity. 
   
   
       9 . Component of a patient interface, particularly a cushion, comprising a first part and a second part, wherein the second part is made of a foamed material which is foamed-on the first part. 
   
   
       10 . Component according to  claim 9 , wherein the second part is a foam, e.g., polyurethane foam or silicone foam and/or wherein the first part is a plastic material, preferably a polymer or a thermoplastic elastomer, which is preferably elastic or hard. 
   
   
       11 . Component according to  claim 9 , wherein the merging or contact surface of the first part is a plane, angled or U-shaped surface structure along at least a portion of the component's circumference, and wherein the second component is foamed-on the first part such that it at least partly merges at the contact or merging surface. 
   
   
       12 . Component according to  claim 9 , constituting a face mask cushion, a forehead pad, and/or a component of a headband for securing a device at a wearer's head. 
   
   
       13 . Component according to  claim 9 , comprising a pressing flange on the first part, wherein the pressing flange, preferably at least partly, defines the boundary of the merging surface. 
   
   
       14 . Tool for manufacturing a component according to  claim 9 , comprising first mold part, a second mold part, a third mold part and a fourth mold part, wherein the first mold part and the second mold part are adapted to define a first cavity, wherein a first part is moldable in the first cavity, and wherein the third mold part, the molded first part and/or the fourth mold part are adapted to define a second cavity, and wherein one or more pressure flange(s) is are provided integrally with the third mold part, the fourth mold part and/or the molded first part, and wherein second mold cavity is preferably adapted to contain the first part and to be filled with a second foamed material. 
   
   
       15 . Tool according to  claim 14 , wherein pressure-flange(s) is/are adapted for sealingly contacting the third mold part, the first part and/or the fourth mold part such that the merging surface between the first part and the second part to be molded in the second cavity is defined by the pressure flange. 
   
   
       16 . Tool according to  claim 14 , wherein the third and/or fourth mold part comprise a sealing means, preferably an O-ring or sealing lip seated in a groove provided in the third and/or fourth mold part, wherein the merging surface between the first part and the second part to be molded in the second cavity is defined by the sealing means.