Patent ID: 8616211

Claim:
A mask assembly for delivering breathable gas to a patient, the assembly comprising: a co-molded frame and cushion structure including: a frame; and a full-face cushion co-molded to the frame and including a nasal bridge region, a pair of side of nose regions, a pair of upper cheek regions, a pair of lower cheek regions and a chin region, the cushion defining, at least in part, a breathing cavity, the cushion comprising: a face-contacting membrane including a nasal bridge region, a pair of side of nose regions, a pair of upper cheek regions, a pair of lower cheek regions and a chin region forming a continuous sealing structure to form a continuous seal on nasal bridge, side of nose, upper cheek, lower cheek and chin regions of the patient's face, the face-contacting membrane having an inner edge that defines a triangular-shaped aperture to receive the patient's nose and mouth; and a support structure to support the face-contacting membrane, the support structure including: a base wall; and an underlying cushion connected to the base wall, the underlying cushion, in a cross-sectional view, extending from the base wall and toward the breathing cavity to provide support for the face-contacting membrane, the underlying cushion including a pair of side of nose regions, a pair of upper cheek regions and a pair of lower cheek regions, such that the underlying cushion and the face-contacting membrane form at least a double-walled construction at least in the pair of side of nose regions, the pair of upper cheek regions and the pair of lower cheek regions of the cushion, said at least double-walled construction being configured such that the underlying cushion is positioned to restrain movement of the face-contacting membrane, wherein, in a cross-sectional view, a widest point of the cushion is an external surface of the underlying cushion or face-contacting membrane, and the base wall is internally offset, with respect to the widest point of the cushion, wherein the cushion has only a single-walled construction formed by the face-contacting membrane in a majority of the chin region of the cushion so as to allow the face-contacting membrane to readily flex in the chin region of the cushion.