Patent ID: 8555885

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 nasal bridge, cheek and chin regions, the cushion defining, at least in part, a breathing cavity, the cushion comprising: a membrane including nasal bridge, cheek and chin regions forming a continuous sealing structure to form a continuous seal on nasal bridge, cheek, and chin regions of the patient's face, the membrane having an inner edge that defines a triangular-shaped aperture; and a support structure to support the membrane, the support structure including: a wall having a top portion and a bottom portion; and a pair of underlying cushions joined in the nasal bridge region of the cushion and extending along the top portion of the wall to provide support to the membrane in the nasal bridge region and cheek regions of the cushion, wherein the membrane extends from the support structure and terminates at the inner edge of the membrane, wherein the pair of underlying cushions extends in the nasal bridge and cheek regions of the cushion such that the membrane and the pair of underlying cushions form at least a double-walled construction in the nasal bridge and cheek regions of the cushion, wherein: each of the pair of underlying cushions extends, in a cross-sectional view, away from the wall and includes an inwardly curved portion that extends into and curves inwardly toward the breathing cavity in a spaced-relationship with respect to the membrane, the membrane, from front view, covers each inwardly curved portion of the pair of underlying cushions, each inwardly curved portion of the pair of underlying cushions terminates at a respective free end, the free ends of the pair of underlying cushions being disposed within the breathing cavity, each said inwardly curved portion of the pair of underlying cushions extends along the nasal bridge and cheek regions of the cushion, and each said inwardly curved portion of the pair of underlying cushions is absent in a majority of the chin region of the cushion to allow the membrane to flex toward the breathing cavity, wherein a first portion of the support structure extends laterally beyond a second exterior portion of the cushion, and wherein: the first portion of the support structure is movable with respect to the second exterior portion of the cushion when the cushion is worn and a force by the frame is exerted on the cushion, the first portion of the support structure is movable from an initial position towards a space exterior of the cushion when the frame force is exerted on the cushion, and the first portion of the support structure is configured to resiliently move back into the initial position when the frame force is no longer exerted on the cushion.