CPAP Mask Repair

Permanently bond the silicone rubber to the plastic of your CPAP mask quickly, easily and permanently with our patented Polymer Bonding Process.

cpap mask

CPAP Mask Repair

The Problem

With CPAP masks, the most common problem is that the silicone rubber separates from the hard plastic of the mask. Both the plastic and silicone rubber are polymers. Our patented Polymer Bonding Process is the only adhesive solutions that will permanently bond the silicone rubber to the clear plastic. The repair will be quick and easy. Most important the repair will be permanent. You will need one fo the Poly Kits to make this repair.

Instructions for Repairing a CPAP Mask

  • Lightly abrade both the silicone rubber and the hard plastic with a fine grit sand paper or an emery file.
  • Clean the abraded area and dry with a soft cloth.
  • Saturate the primed surfaces with the Poly Prep (PP).. Let dry.
  • Spray a light mist of the Activator/Accelerator (AA) on the hard plastic. Let dry.
  • Warm both the silicone rubber and the hard plastic with a heat source (hair dryer or heat gun) to about 120 degrees F or, by touch just below hot.
  • Apply the SI adhesive to the prepped area of the mask.
  • Stretch the silicone rubber over the hard plastic, align and press the surfaces together.
  • Apply pressure over the entire joined area for 15-39 seconds,

The silicone rubber will be permanently bonded to the hard plastic. Watch the video below for more information.

Step by step instructions

Press the following button to download step-by-step instructions on how to repair a CPAP machine that has split the silicone rubber from the hard plastic.

Repair CPAP Mask Instsructions

Case study

We will start by thanking the couple that sent in the CPAP mask for use to repair. We greatly appreciate the opportunity to make repairs on items, like the CPAP mask, that are both a poly and expensive. Such generosity will enable us to get the “how to” information out to those in need much more quickly. If you have such an item we would appreciate hearing from you.

This sample mask has the same problems that affect most masks, the flexible part of the mask, i.e., the silicone rubber, separated from the hard plastic of the mask. Both materials are poly’ and our patented Polymer Bonding Process (Process) is the most effective way, by far, to bond polymers, to themselves or to each other. It is important to understand that bonds created by the Process are permanent.

With the sample mask, the separation of the silicone rubber from the plastic was more severe than the norm. There was about sixty percent separation of the two materials which increased the level of difficulty in the repair. An outline of the steps of the repair are given below.

  • We abraded the surfaces of the area to be joined with a 120 grit sandpaper. An emery board will also work. After etching you clean off the residue. All residue, dirt, grease, or corrosion must be removed. If a cleaner is used, make sure it is one that will not leave a residue.
  • We saturated the surfaces to be joined with our Poly Prep (PP). The key to making the Poly Prep effective is having the surface(S) look “wet”. The Poly Prep etches the surface and needs time to complete that task. Once the PP liquid flashes off, the etching stops. One coating of the PP is good, two is better.
  • Then surfaces were warmed to about 120 degrees F. You want the surfaces to be as warm as it can be without actually being hot. Besides a heat gun you can also use a hairdryer to warm the surfaces.
  • Because heat changes the handling characteristics of polymers, especially silicone rubber, It is important to practice in order to efficiently make the repair. In this case, the challenged was heightened because the heat stretched the silicone rubber. We ended up bonding the bottom of the U of the silicone rubber to the hard plastic and worked back.
  • After practicing, we rewarmed the surfaces, and Immediately applied a thin coat of SI adhesive to the far end of the hard plastic.
  • We stretched the silicone rubber over the far end of the hard plastic, aligned and pressed the two surfaces together.
  • Sprayed the seam with the Activator/Accelerator (AA).
  • Then we did the same procedure of applying the SI adhesive, pressing the surfaces together and spraying the AA down each side.
  • We inspected the repair for any problems. There wasn’t any this time. If there had been, we would have resolved the issues by using the above procedure.

When the silicone rubber cooled off and retracted, we had an exceptional repair.

Questions? Please call 877 565 7225.

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