My recommendation would be to obtain the UV adhesive that is currently being advertised on TV. It should help in a pinch. We have a drugstore chain in my area that sells "as Seen on TV" products.
One thing that may help in the future would be to minimize the number of times you pop the cushion out of the frame. If you use the all plastic frame, there's no reason to wash the cushion separately from the frame - except it's a little clumsy. If using the fabric covered frame (as I will be soon), a daily wipe-down of the cushion, with weekly removal and washing of the cushion, should prolong the life of the frame.
From a design standpoint, strengthening the frame around the cushion would make it heavier and harder to remove and replace the cushion. Since the insurance companies seem happy with a 6-month replacement cycle, why not? It costs less to make, and you'll sell more of them. What's not to like? Assuming 'you' are the manufacturer...
If you want to use to destruction, you can pick up just a frame as soon as you see the tear developing, of course.
Thanks everyone for the helpful details !!!
I use and love this mask. I change the frame every 3 months, as recommended, and have never seen such an issue. At what interval are you replacing your frame? The Fabric frame seems to last very well, and I've not seen any indications of a problem around the hose attachment point. Not sure why your experience is so different, as I am also a very active sleeper.
What do you think is the cause?
Not your problem point, but I thought others might be interested in this solution for another weak area, the button hole on the frame. My DME sent me home with a set of demo magnets made specifically for the wisp by PR. They attach one side to the frame opening where the button would attach, and the other where you remove the button from the head gear. Much more convenient, they snap together when somewhat close to each other. Should save wear and tear on the frame button hole. I use a clear frame and on a negative note they do leave about a nickel size mark where they touch my cheek.
I've been using a Wisp Mask for around 2 years, got over 12 months out of the first silicon/plastic frame, then switched to the fabric frame and got less than 3 months use before it came apart, back to the silicon/plastic frame then and still working a treat after over 9 months. Would not even consider a fabric frame ever again, and anyhow my main supplier no longer keeps the fabric frames as she had so many complaints the same as mine.