Xiamen Better Silicone Rubber Co., Ltd
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CPAP Mask also called nasal mask, full face mask, pillow mask, full name is continuous positive airway pressure (CPAP) therapy, one of the most common ways to reduce many of the symptoms associated with sleep apnea. CPAP mask therapy transports pressurized air to the sleeper’s breathing passages to help prevent airway collapse. Generally, CPAP mask is consist of a silicone mask cushion, plastic mask frame, mask hosing, and mask headgear.
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CPAP Mask is a kind of medical device designed to cover on a patient’s face during CPAP therapy, there are different CPAP masks to fit for different sleepers/patients, full face mask, nasal pillow mask, nasal CPAP mask, nasal pillow mask, masks fit over or under the nose, nostrils, mouth, face, or all. Full face mask is most commonly clear/high transparent, won’t blend sleeper’s sighting to make user be nervous, and manufacturers always make masks as low-profile as possible to ensure that face masks stay securely attached during sleep. A good therapy mask should be both comfortable and functional. Among all CPAP mask components, cushion is very important that plays role in sealing around or beneath user’s mouth or nose, connected to mask frame, mask cushion is replaceable and the whole part is cleanable. Generally, mask cushion is made of medical grade soft flexible silicone, always made by liquid silicone injection molding (LIM). Cleaning and replacing CPAP cushion regularly helps prevent buildup from bacteria and mildew.
CPAP Mask Types:
There are kinds of different CPAP masks available in markets. Two basic standards of all CPAP masks are fitting nice, and comfortable.
Nasal Pillow CPAP Mask
CPAP nasal pillows have a low-profile design structure that fits between the patient’s nose and under lip, also named nostril pillow, creating a great seal to nose without air leaks. On the pillow mask there are two small short prongs/tips fitting into nose nostril to deliver oxygen to user, mask prongs are soft, elastic, and lightweight, easy to insert into nostril without discomfort.
Full-Face CPAP Mask
Nasal Prong CPAP Masks
Oral CPAP Masks
Hybrid CPAP Masks
Total Face CPAP Masks
CPAP Face Mask - How To Manufacture? - Workshop Production Process
Full face mask structure: clear mask frame with headgear connecting hols, oxygen connection hole, soft flexible mask cushion, and check valve for oxygen delivery.
Main materials of producing CPAP mask: generally, the mask body/frame is made from hard plastic - medical grade PC, Polycarbonate (PC) is an amorphous clear plastic suitable for industrial engineering. This versatile thermoplastic polymer is easy to process and has many applications within different branches. PC plastic is mainly used for medical devices and parts, but can also be used as a stronger substitute for glass. PC mask frame with many advantages: Highly impact resistant – at least 250 times stronger than glass; Suitable for intensive use; Resistant to high temperatures; Bendable; Easy to process; Light transmittance; Easy to shape. To sum up, Polycarbonates are strong, stiff, hard, tough, transparent engineering thermoplastics that can maintain rigidity up to 140°C and toughness down to -20°C or special grades even lower.
Why choose liquid silicone rubber to form mask cushion/pillow?
liquid silicone rubber has a high degree of elasticity and compressibility, resilience and weatherability. You can use LSR at temperatures between -40°C to 200°C (-40°F – 392°F), expose it to wind, rain and UV light for extended periods of time, or immerse it in water, oil or solvents.Whether you have medical products for drug delivery or pumping applications that require strength, flexibility and repeatability, or automotive components that must withstand excessive heat and vibration, liquid silicone’s mechanical properties make it an excellent material choice. Above properties make liquid silicone rubber is used across multiple industries, especially for medical and life sciences and baby products. Not only mask cushion, oxygen mask check valves and seals rings can also be produced by LSR injection molding.
Process: CPAP mask is over-molding technology: firstly form the PC plastic mask frame by plastic injection molding, before over-molding with liquid silicone rubber, should clean the frame and apply primer to edge of PC mask frame to enhance the bonding between two types of materials, then put the formed plastic frame (has been applied with primer) onto LSR injection mold tool cavities/cores to locate and cure, after about 100 seconds, LSR mold open automatically and demould/take out the finalized face mask.
(Note: for nasal face mask, generally need separate mold cores structure in LIM tool. Nasal pillow / pillow mask process is similar to above CPAP mask.)
Relevant medical products made from liquid silicone rubber / plastic over-molding:
CPAP Mask is a kind of medical device designed to cover on a patient’s face during CPAP therapy, there are different CPAP masks to fit for different sleepers/patients, full face mask, nasal pillow mask, nasal CPAP mask, nasal pillow mask, masks fit over or under the nose, nostrils, mouth, face, or all. Full face mask is most commonly clear/high transparent, won’t blend sleeper’s sighting to make user be nervous, and manufacturers always make masks as low-profile as possible to ensure that face masks stay securely attached during sleep. A good therapy mask should be both comfortable and functional. Among all CPAP mask components, cushion is very important that plays role in sealing around or beneath user’s mouth or nose, connected to mask frame, mask cushion is replaceable and the whole part is cleanable. Generally, mask cushion is made of medical grade soft flexible silicone, always made by liquid silicone injection molding (LIM). Cleaning and replacing CPAP cushion regularly helps prevent buildup from bacteria and mildew.
CPAP Mask Types:
There are kinds of different CPAP masks available in markets. Two basic standards of all CPAP masks are fitting nice, and comfortable.
Nasal Pillow CPAP Mask
CPAP nasal pillows have a low-profile design structure that fits between the patient’s nose and under lip, also named nostril pillow, creating a great seal to nose without air leaks. On the pillow mask there are two small short prongs/tips fitting into nose nostril to deliver oxygen to user, mask prongs are soft, elastic, and lightweight, easy to insert into nostril without discomfort.
Full-Face CPAP Mask
Nasal Prong CPAP Masks
Oral CPAP Masks
Hybrid CPAP Masks
Total Face CPAP Masks
CPAP Face Mask - How To Manufacture? - Workshop Production Process
Full face mask structure: clear mask frame with headgear connecting hols, oxygen connection hole, soft flexible mask cushion, and check valve for oxygen delivery.
Main materials of producing CPAP mask: generally, the mask body/frame is made from hard plastic - medical grade PC, Polycarbonate (PC) is an amorphous clear plastic suitable for industrial engineering. This versatile thermoplastic polymer is easy to process and has many applications within different branches. PC plastic is mainly used for medical devices and parts, but can also be used as a stronger substitute for glass. PC mask frame with many advantages: Highly impact resistant – at least 250 times stronger than glass; Suitable for intensive use; Resistant to high temperatures; Bendable; Easy to process; Light transmittance; Easy to shape. To sum up, Polycarbonates are strong, stiff, hard, tough, transparent engineering thermoplastics that can maintain rigidity up to 140°C and toughness down to -20°C or special grades even lower.
Why choose liquid silicone rubber to form mask cushion/pillow?
liquid silicone rubber has a high degree of elasticity and compressibility, resilience and weatherability. You can use LSR at temperatures between -40°C to 200°C (-40°F – 392°F), expose it to wind, rain and UV light for extended periods of time, or immerse it in water, oil or solvents.Whether you have medical products for drug delivery or pumping applications that require strength, flexibility and repeatability, or automotive components that must withstand excessive heat and vibration, liquid silicone’s mechanical properties make it an excellent material choice. Above properties make liquid silicone rubber is used across multiple industries, especially for medical and life sciences and baby products. Not only mask cushion, oxygen mask check valves and seals rings can also be produced by LSR injection molding.
Process: CPAP mask is over-molding technology: firstly form the PC plastic mask frame by plastic injection molding, before over-molding with liquid silicone rubber, should clean the frame and apply primer to edge of PC mask frame to enhance the bonding between two types of materials, then put the formed plastic frame (has been applied with primer) onto LSR injection mold tool cavities/cores to locate and cure, after about 100 seconds, LSR mold open automatically and demould/take out the finalized face mask.
(Note: for nasal face mask, generally need separate mold cores structure in LIM tool. Nasal pillow / pillow mask process is similar to above CPAP mask.)
Relevant medical products made from liquid silicone rubber / plastic over-molding:
