Respiratory interface assembly

Abstract

The respiratory interface assembly includes a patient interface, such as a nasal mask, and a headgear configuration. The headgear configuration may have one or more semi-rigid straps, which may be a composite structure of an outer fabric and a plastic core. The outer fabric may be knitted. The headgear configuration may include a composite rear portion having upper and lower straps configured to be adjustable relative to one another.

Description

Technical Field

[0001] Cross - Reference to Related Applications All applications for which foreign or domestic priority claims are listed in the application data sheet filed together with this application are hereby incorporated by reference into this specification and made a part of this disclosure.

Background Art

[0002] This disclosure relates to a respiratory interface assembly. In particular, this disclosure relates to the headgear of a respiratory interface assembly.

[0003] In assisted respiration, breathing gas is supplied to a patient through one or more flexible breathing tubes and through a patient interface. The patient interface can be a nasal cannula, a nasal mask, a full - face or oro - nasal mask, an endotracheal tube, or other known types of interfaces. The patient interface is held in a predetermined position on the user's head by a headgear configuration.

[0004] When a reference is made in this specification to a patent specification, other external document, or other information source, this is generally for the purpose of providing context for explaining the features of this disclosure. Unless specifically stated otherwise, such reference to an external document should not be construed in any jurisdiction as an admission that such document or such information source is prior art or forms part of the common general knowledge in the art.

Summary of the Invention

Means for Solving the Problems

[0005] The systems, methods, and devices described herein have innovative aspects, none of which are essential to their desirable characteristics, nor do any of them alone cause their desirable characteristics. Here, without limiting the scope of the claims, some of the advantageous features are outlined.

[0006] One aspect of the present disclosure includes a rear portion of a breathing mask headgear, which includes a one-piece body portion made of plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first and second ends, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first and second ends, and a width. The body portion includes a joint between the first end of the upper strap and the first end of the lower strap. The joint includes a base portion and a transition area between the base portion and one of the upper and lower straps. The base portion defines a width. The width of the transition area is less than the width of the base portion of the joint and the width of each upper or lower strap to which the transition area is joined.

[0007] In some configurations, the width of the transition area is less than approximately half the width of each upper or lower strap to which the transition area is joined.

[0008] In some configurations, the width of the transition area is less than approximately one-third of the width of each upper or lower strap to which the transition area is joined.

[0009] In some configurations, the transition area is defined by a length smaller than the width of the base of the joint and / or the width of each upper or lower strap to which the transition area is joined.

[0010] In some configurations, the length of the transition area is less than approximately two-thirds or one-half of the width of each upper or lower strap to which the transition area is joined.

[0011] In some configurations, the transition area is defined by slots, each slot having a maximum width less than the width of the base of the joint and / or the width of each upper or lower strap adjacent to the slot.

[0012] In some configurations, the joint is symmetrical with respect to an axis passing through the joint and between the upper and lower straps.

[0013] In some configurations, each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, wherein the main strap portion extends along the entire length of the strap and the at least one flange portion extends along most of the length of the strap.

[0014] In some configurations, at least one flange extends along only a portion of the strap's length.

[0015] In some configurations, the main strap section, or the main strap section and flange, define the entire width of the strap at any point along the length of the strap.

[0016] In some configurations, the main strap section defines the entirety of either the upper edge or the lower edge of the strap.

[0017] In some configurations, the main strap section defines the entire width of the central part of the strap.

[0018] In some configurations, at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

[0019] In some configurations, during use, the first flange portion and the second flange portion each extend substantially along the entire length of each side of the user's head.

[0020] In some configurations, the length of the upper strap is the first length, and the length of the lower strap is the second length, with the second length being greater than the first length.

[0021] In some configurations, the width of the lower strap is greater than the width of the upper strap.

[0022] In some configurations, the central portion of the upper strap is defined as having a shorter length than the central portion of the lower strap.

[0023] In some configurations, the transition region is the first transition region, the joint further includes a second transition region, the first transition region is located between the base portion and the upper strap, and the second transition region is located between the base portion and the lower strap.

[0024] In some configurations, the width of the second transition region is greater than the width of the first transition region.

[0025] In some configurations, the body portion includes a fabric inner layer, a fabric outer layer, and an internal plastic layer, and the internal plastic layer is permanently joined as an integral structure by introducing the internal plastic layer in a molten state into the space between the fabric inner layer and the fabric outer layer and curing it.

[0026] In some configurations, the fabric inner layer and the fabric outer layer are woven.

[0027] In some configurations, the fabric inner layer and the fabric outer layer are joined to form an edge fabric layer along the upper and lower edges of the upper and lower straps.

[0028] In some configurations, the thickness of the edge fabric layer along the upper and lower edges of the upper and lower straps is greater than the thickness of the fabric inner layer and the fabric outer layer.

[0029] In some configurations, the rear portion further includes at least one fabric layer configured to enclose the internal plastic layer. The at least one fabric layer may include at least one width. The at least one width may include a transition region width disposed adjacent to the transition region.

[0030] In some configurations, the at least one fabric layer may include at least one upper strap fabric layer and at least one lower strap fabric layer.

[0031] In some configurations, at least one width may include the width of the upper strap of at least one upper strap fabric layer and the width of the lower strap of at least one lower strap fabric layer.

[0032] In some configurations, at least one fabric layer may include an upper strap width along the upper strap and a lower strap width along the lower strap.

[0033] In some configurations, the transition area width may be the same as or similar to the upper strap width.

[0034] In some configurations, the transition area width may be the same as or similar to the lower strap width.

[0035] In some configurations, the width of the lower strap can be greater than the width of the upper strap.

[0036] In some configurations, the width of the transition region of at least one fabric layer can be greater than the width of the transition region of the joint.

[0037] In some configurations, at least one fabric layer may include at least one fabric flap adjacent to the transition region. The width of at least one fabric flap may be maximum at the point where the width of the transition region is minimum.

[0038] In some configurations, the joint between the first end of the upper strap and the first end of the lower strap is the first joint, and a second joint is further included between the second end of the upper strap and the second end of the lower strap, the second joint including a transition area between the base and one or both of the upper and lower straps.

[0039] One aspect of the present disclosure includes a breathing mask headgear comprising one of the rear portions described above and a pair of side straps. Each side strap extends from one of the first joints and one of the second joints, respectively. Each side strap includes an elongated plastic member bonded to the plastic material of the main body portion of the rear portion.

[0040] In some configurations, each elongated plastic component of the side strap is joined to the main body's plastic material by a overlapping connector.

[0041] In some configurations, each side strap includes a hub at the end of an elongated plastic member, the hub including a port configured to receive molten plastic material that forms the rear body portion.

[0042] In some configurations, the hub further includes a channel connected to the port, which is configured to allow molten plastic material to exit the hub and flow into the space between the inner and outer fabric layers.

[0043] In some configurations, each side strap further includes inner and outer fabric layers connected to the inner and outer fabric layers of the rear portion.

[0044] In some configurations, the inner and outer fabric layers of the side straps are relatively elastic, while the inner and outer fabric layers of the rear portion are relatively inelastic.

[0045] In some configurations, the inner and outer fabric layers of the side straps are formed together with the inner and outer fabric layers of the rear portion as a single knitted structure.

[0046] One aspect of the present disclosure includes a breathing mask assembly comprising any one of the headgears described above, a breathing mask, and a first directional lock and a second directional lock coupled to the breathing mask. Each elongated plastic member of each side strap includes a filament portion, each filament portion of the side strap passing through one of the first directional lock and the second directional lock, each of which is configured to provide a first resistance force against the movement of the filament portion in a first direction that tends to extend the side strap and a second resistance force against the movement of the filament portion in a second direction that tends to shorten the side strap, the first resistance force being greater than the second resistance force.

[0047] In some configurations, the first resistance force is configured to prevent the movement of the filament in a first direction in response to the blow-off force generated by the breathing mask.

[0048] In some configurations, the second resistance force is smaller than the elastic forces of the inner and outer fabric layers of the side strap, so that the elastic force can move the filament portion in the second direction and shorten the side strap.

[0049] In some configurations, the breathing mask is a nasal mask.

[0050] One aspect of the present disclosure includes a rear portion of a breathing mask headgear, which includes a one-piece body portion made of plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first and second ends, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first and second ends, and a width. The body portion includes a joint between the first end of the upper strap and the first end of the lower strap, which includes a base portion and a living hinge between the base portion and one of the upper and lower straps.

[0051] In some configurations, the living hinge defines a length smaller than the width of the base of the joint and / or the width of each upper or lower strap to which the living hinge is joined.

[0052] In some configurations, the length of the living hinge is less than approximately two-thirds or one-half of the width of each upper or lower strap to which the living hinge is joined.

[0053] In some configurations, the living hinge is defined by a slot.

[0054] In some configurations, the joint is symmetrical with respect to an axis passing through the joint and between the upper and lower straps.

[0055] In some configurations, each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, the main strap portion extending along the entire length of the strap from a first joint to a second joint, and the at least one flange portion extending along most of the length of the strap.

[0056] In some configurations, at least one flange extends along only a portion of the strap's length.

[0057] In some configurations, the main strap section, or the main strap section and flange, define the entire width of the strap at any point along the length of the strap.

[0058] In some configurations, the main strap section defines the entirety of either the upper edge or the lower edge of the strap.

[0059] In some configurations, the main strap section defines the entire width of the central part of the strap.

[0060] In some configurations, at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

[0061] In some configurations, during use, the first flange portion and the second flange portion each extend substantially along the entire length of each side of the user's head.

[0062] In some configurations, the length of the upper strap is the first length, and the length of the lower strap is the second length, with the second length being greater than the first length.

[0063] In some configurations, the width of the lower strap is greater than the width of the upper strap.

[0064] In some configurations, the length of the central part of the upper strap is defined as being shorter than the length of the central part of the lower strap.

[0065] In some configurations, the living hinge is a first living hinge, and the joint further includes a second living hinge, the first living hinge located between the base and the upper strap, and the second living hinge located between the base and the lower strap.

[0066] In some configurations, the main body includes a fabric inner layer, a fabric outer layer, and an internal plastic layer, the internal plastic layer being introduced in a molten state into the space between the fabric inner layer and the fabric outer layer and cured to permanently join them as a single structure.

[0067] In some configurations, the inner and outer layers of fabric are knitted.

[0068] In some configurations, the inner and outer layers of fabric are joined together to form an edge fabric layer along the upper and lower edges of the upper and lower straps.

[0069] In some configurations, the thickness of the edge fabric layer along the upper and lower edges of the upper and lower straps is greater than the thickness of the inner and outer fabric layers.

[0070] In some configurations, the joint between the first end of the upper strap and the first end of the lower strap is the first joint, and a second joint is further included between the second end of the upper strap and the second end of the lower strap, the second joint including a base and a living hinge between one or both of the upper and lower straps.

[0071] One aspect of the present disclosure includes a breathing mask headgear comprising one of the aforementioned rear portions and a pair of side straps. Each side strap extends from one of the first joint and one of the second joints, respectively. Each side strap includes an elongated plastic member bonded to the plastic material of the main body portion of the rear portion.

[0072] In some configurations, the elongated plastic components of each side strap are joined to the main body's plastic material by overlapping, molded connectors.

[0073] In some configurations, each side strap includes a hub at the end of an elongated plastic member, the hub including a port configured to receive molten plastic material that forms the rear body portion.

[0074] In some configurations, the hub further includes a channel connected to the port, which is configured to allow molten plastic material to exit the hub and flow into the space between the inner and outer fabric layers.

[0075] In some configurations, each side strap further includes inner and outer fabric layers connected to the inner and outer fabric layers of the rear portion.

[0076] In some configurations, the inner and outer fabric layers of the side straps are relatively elastic, while the inner and outer fabric layers of the rear portion are relatively inelastic.

[0077] In some configurations, the inner and outer fabric layers of the side straps are formed together with the inner and outer fabric layers of the rear portion as a single knitted structure.

[0078] One aspect of the present disclosure includes a breathing mask assembly comprising any of the headgears described above, a breathing mask, and a first directional lock and a second directional lock coupled to the breathing mask. Each elongated plastic member of each side strap includes a filament portion, each filament portion of the side strap passing through one of the first directional lock and the second directional lock, each of which is configured to provide a first resistance force against the movement of the filament portion in a first direction that tends to extend the side strap and a second resistance force against the movement of the filament portion in a second direction that tends to shorten the side strap, the first resistance force being greater than the second resistance force.

[0079] In some configurations, the first resistance force is configured to prevent the movement of the filament in a first direction in response to the blowing force generated by the breathing mask.

[0080] In some configurations, the second resistance force is smaller than the elastic forces of the inner and outer fabric layers of the side strap, so that the elastic force can move the filament portion in the second direction and shorten the side strap.

[0081] In some configurations, the breathing mask is a nasal mask.

[0082] One aspect of the present disclosure includes a rear portion of a breathing mask headgear, comprising an upper strap having a first end, a second end, and a first length between the first and second ends. The rear portion also comprises a lower strap having a first end, a second end, and a second length between the first and second ends. The first end of the upper strap is connected to the first end of the lower strap, and the second end of the upper strap is connected to the second end of the lower strap. The second length is greater than the first length.

[0083] One aspect of the present disclosure includes a rear portion of a breathing mask headgear, which includes a one-piece body portion made of plastic material. The body portion includes an upper strap having a lower edge, a first end, a second end, a length between the first and second ends, and a width. The body portion also includes a lower strap having an upper edge, a first end, a second end, a length between the first and second ends, and a width. A separation distance is defined between the lower edge of the upper strap and the upper edge of the lower strap. A joint is located between the end of the upper strap and the end of the lower strap. The joint includes a base portion and a flex region between the base portion and one of the upper and lower straps. The flex region is configured to pivot each upper or lower strap to which the flex region is joined relative to the base portion of the joint, thereby increasing the separation distance.

[0084] In some configurations, the joint is configured to increase the separation distance until an angle of at least approximately 90 degrees is formed between the upper and lower straps.

[0085] In some configurations, the joint is configured to increase the separation distance until an angle of at least approximately 135 degrees is formed between the upper and lower straps.

[0086] In some configurations, the width of the flex zone is less than approximately half the width of each upper or lower strap to which the flex zone is joined.

[0087] In some configurations, the width of the flex zone is less than approximately one-third of the width of each upper or lower strap to which the flex zone is joined.

[0088] In some configurations, the flex zone is defined by a length smaller than the width of the base of the joint and / or the width of each upper or lower strap to which the flex zone is joined.

[0089] In some configurations, the length of the flex zone is less than approximately two-thirds or one-half of the width of each upper or lower strap to which the flex zone is joined.

[0090] In some configurations, the flex area is defined by slots having a maximum width smaller than the width of the base of the joint and / or the width of each upper or lower strap adjacent to the slot.

[0091] In some configurations, the joint is symmetrical with respect to an axis passing through the joint and between the upper and lower straps.

[0092] In some configurations, each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, wherein the main strap portion extends along the entire length of the strap and the at least one flange portion extends along most of the length of the strap.

[0093] In some configurations, at least one flange extends along only a portion of the strap's length.

[0094] In some configurations, the main strap section, or the main strap section and flange, define the entire width of the strap at any point along the length of the strap.

[0095] In some configurations, the main strap section defines the entirety of either the upper edge or the lower edge of the strap.

[0096] In some configurations, the main strap section defines the entire width of the central part of the strap.

[0097] In some configurations, at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

[0098] In some configurations, during use, the first flange portion and the second flange portion each extend substantially along the entire length of each side of the user's head.

[0099] In some configurations, the length of the upper strap is the first length, and the length of the lower strap is the second length, with the second length being greater than the first length.

[0100] In some configurations, the width of the lower strap is greater than the width of the upper strap.

[0101] In some configurations, the central portion of the upper strap is defined as having a shorter length than the central portion of the lower strap.

[0102] In some configurations, the flex region is a first flex region, and the joint further includes a second flex region, the first flex region located between the base and the upper strap, and the second flex region located between the base and the lower strap.

[0103] In some configurations, the main body includes a fabric inner layer, a fabric outer layer, and an internal plastic layer, the internal plastic layer being introduced in a molten state into the space between the fabric inner layer and the fabric outer layer and cured to permanently join them as a single structure.

[0104] In some configurations, the inner and outer layers of fabric are knitted.

[0105] In some configurations, the inner and outer layers of fabric are joined together to form an edge fabric layer along the upper and lower edges of the upper and lower straps.

[0106] In some configurations, the thickness of the edge fabric layer along the upper and lower edges of the upper and lower straps is greater than the thickness of the inner and outer fabric layers.

[0107] In some configurations, the joint between the first end of the upper strap and the first end of the lower strap is the first joint, and the rear portion further includes a second joint between the second end of the upper strap and the second end of the lower strap. The second joint includes a flex area between the base portion and one or both of the upper and lower straps.

[0108] One aspect of the present disclosure includes a breathing mask headgear comprising any of the rear portions described above and a pair of side straps, each of which side straps extends from one of the first joints and one of the second joints, and each side strap comprises an elongated plastic member coupled to the plastic material of the main body portion of the rear portion.

[0109] In some configurations, the elongated plastic components of each side strap are joined to the main body's plastic material by overlapping, molded connectors.

[0110] In some configurations, each side strap includes a hub at the end of an elongated plastic member, the hub including a port configured to receive molten plastic material that forms the rear body portion.

[0111] In some configurations, the hub further includes a channel connected to the port, which is configured to allow molten plastic material to exit the hub and flow into the space between the inner fabric layer and the outer fabric layer.

[0112] In some configurations, each side strap further includes inner and outer fabric layers connected to the inner and outer fabric layers of the rear portion.

[0113] In some configurations, the inner and outer fabric layers of the side straps are relatively elastic, while the inner and outer fabric layers of the rear portion are relatively inelastic.

[0114] In some configurations, the inner and outer fabric layers of the side straps are formed together with the inner and outer fabric layers of the rear portion as a single knitted structure.

[0115] One aspect of the present disclosure includes a breathing mask assembly having any of the headgears described above, a breathing mask, and a first directional lock and a second directional lock coupled to the breathing mask. Each elongated plastic member of each side strap includes a filament portion. Each filament portion of each side strap passes through one of the first directional lock and the second directional lock. Each of the first and second directional locks is configured to provide a first resistance force against the movement of the filament portion in a first direction that tends to extend the side strap and a second resistance force against the movement of the filament portion in a second direction that tends to shorten the side strap. The first resistance force is greater than the second resistance force.

[0116] In some configurations, the first resistance force is configured to prevent the movement of the filament in a first direction in response to the blowing force generated by the breathing mask.

[0117] In some configurations, the second resistance force is smaller than the elastic forces of the inner and outer fabric layers of the side strap, so that the elastic force can move the filament portion in the second direction and shorten the side strap.

[0118] In some configurations, the breathing mask is a nasal mask.

[0119] One aspect of the present disclosure includes a rear portion of a breathing mask headgear, comprising a one-piece body portion made of a plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first and second ends, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first and second ends, and a width. The body portion includes a first joint and a second joint. The first joint is located between the first end of the upper strap and the first end of the lower strap, and the second joint is located between the second end of the upper strap and the second end of the lower strap. Each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness. The main strap portion extends along the entire length of the strap from the first joint to the second joint. The at least one flange portion extends along most of the length of the strap.

[0120] In some configurations, at least one flange extends along only a portion of the strap's length.

[0121] In some configurations, the main strap section, or the main strap section and flange, define the total width of the strap at any point along the length of the strap.

[0122] In some configurations, the main strap section defines the entirety of either the upper edge or the lower edge of the strap.

[0123] In some configurations, the main strap section defines the entire width of the central part of the strap.

[0124] In some configurations, at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

[0125] In some configurations, during use, the first flange portion and the second flange portion each extend substantially along the entire length of each side of the user's head.

[0126] In some configurations, the length of the upper strap is the first length, and the length of the lower strap is the second length, with the second length being greater than the first length.

[0127] In some configurations, each of the first and second joints includes a base and a flexible region between the base and one or both of the upper and lower straps, the flexible region being configured to pivot each upper or lower strap to which the flexible region is joined relative to the base, thereby increasing the separation distance between the lower edge of the upper strap and the upper edge of the lower strap.

[0128] In some configurations, the base section defines a width, and the flex area includes a transition area that defines a width smaller than the width of the base section of the joint and the width of each upper or lower strap to which the flex area is joined.

[0129] In some configurations, the flex zone includes a living hinge.

[0130] One aspect of the present disclosure includes a pair of side straps for a breathing mask headgear, each comprising an elongated plastic member and a support housing. The elongated plastic member may comprise a first portion, a second portion, a hub, and a transition portion. The first portion may comprise a first end and a second end. The second end may comprise a mechanical stop portion extending radially outward from the elongated plastic member. The mechanical stop portion may define an extended hard stop. The second width may be smaller than the width of the first portion. The hub may comprise a first end opposite to the second end. The second end of the hub may comprise a contact surface that can define a retractable hard stop. The second end of the hub may be adjacent to the first end of the first portion. The transition portion may be positioned between the second end of the first portion and the second end of the second portion. The support housing may be configured to restrain at least a portion of the elongated plastic member. The support housing may define an internal channel configured to receive an elongated plastic member. The support housing may include an outer collar, an inner collar, and an intermediate section between the outer collar and the inner collar.

[0131] In some configurations, the outer wall of the outer collar may define a first contact surface of the outer collar, configured to contact the contact surface of the hub, and the inner wall of the outer collar may define a second contact surface, configured to contact the mechanical stop.

[0132] In some configurations, each side strap may further include at least one length that may include a maximum length and a minimum length.

[0133] In some configurations, the pair of side straps may include a minimum length when the first contact surface of the outer collar contacts the contact surface of the hub.

[0134] In some configurations, the pair of side straps may include the maximum length when the second contact surface of the outer collar contacts the mechanical stop.

[0135] In some configurations, the hub may be substantially rectangular, and the length of the hub may be greater than the width of the hub.

[0136] In some configurations, the hub may include a first side facing a second side. The length of the first side may be greater than the length of the second side. The width of the first side may be greater than the width of the second side.

[0137] In some configurations, the width of the first side of the hub may be measured between the first side of the first part and the first outer edge of the first side of the hub. The width of the second side may be measured between the second side of the first part and the second outer edge of the second side of the hub.

[0138] In some configurations, the hub and the first part may include their respective outer and inner surfaces.

[0139] In some configurations, the outer surface of the first part may be continuous with the outer surface of the hub.

[0140] In some configurations, the hub may include a hub thickness, and the first part may include a first thickness. The hub thickness may be greater than the first thickness. The hub thickness may be measured between the outer and inner surfaces of the hub. The first thickness may be measured between the outer and inner surfaces of the first part.

[0141] In some configurations, the inner surface of the hub may be offset from the inner surface of the first part.

[0142] In some configurations, the offset between the inner surface of the hub and the first part can define the contact surface of the hub.

[0143] One aspect of the present disclosure includes a breathing mask headgear comprising either of the above pairs of straps and a rear portion. The rear portion may include a one-piece body portion comprising a plastic material. The one-piece body portion may include an upper strap, a lower strap, a first joint, and a second joint. The upper strap may have a first end, a second end, a length between the first and second ends, and a width. The lower strap may have a first end, a second end, a length between the first and second ends, and a width. The first joint may be located between the first end of the upper strap and the first end of the lower strap. The second joint may be located between the second end of the upper strap and the second end of the lower strap. Each of the side straps may extend from one of the first joints and one of the second joints. The first end of the hub of each side strap may be overlap-molded onto one of the first joints and one of the second joints. The second end of each side strap hub may remain uncovered.

[0144] One aspect of the present disclosure includes a pair of side straps for a breathing mask headgear, each of which may include an elongated plastic member. The elongated plastic member includes a first portion, a second portion, and a hub. The first portion may include a first end, a second end, an inner surface, an outer surface, and a first portion thickness measured between the inner surface and the outer surface of the first portion. The width of the second portion may be smaller than the width of the first portion. The hub may include a first end facing the second end, a first side facing the second side, an inner surface, an outer surface continuous with the outer surface of the first portion, and a hub thickness measured between the inner surface and the outer surface of the hub. The hub thickness may be larger than the first portion thickness. The second end of the hub may be adjacent to the first end of the first portion and may include a contact surface that can define a retraction hard stop. The first and second sides of the hub may extend between the first and second ends of the hub and may be separated by the longitudinal axis of the first portion. The first length of the first side of the hub may be greater than the second length of the second side of the hub. The first width of the first side of the hub may be greater than the second width of the second side of the hub.

[0145] In some configurations, the first width of the first side of the hub may be measured between the longitudinal axis of the first portion and the first outer edge of the first side of the hub. The first outer edge of the hub may be substantially parallel to the longitudinal axis of the first portion.

[0146] In some configurations, the second width of the second side of the hub may be measured between the longitudinal axis of the first portion and the second outer edge of the second side of the hub. The second outer edge of the hub may be substantially parallel to the longitudinal axis of the first portion.

[0147] In some configurations, the first length of the first side of the hub may be measured between the first end and the second end of the hub.

[0148] In some configurations, the second length of the second side of the hub may be measured between the first end and the second end of the hub.

[0149] In some configurations, the first end of the first side of the hub may be continuous with the first end of the second side of the hub.

[0150] In some configurations, the second end of the first side of the hub may be offset from the second end of the second side of the hub.

[0151] In some configurations, the offset between the second end of the first side of the hub and the second end of the second side of the hub may define an oriented notch.

[0152] In some configurations, the inner surface of the hub may be offset from the inner surface of the first part.

[0153] In some configurations, the offset between the inner surface of the hub and the inner surface of the first part can define the contact surface of the hub. The contact surface may be located at the second end of the hub.

[0154] In some configurations, the second end of the first part may include a mechanical stop extending radially outward from the outer surface of the first part. The mechanical stop may define an extended hard stop.

[0155] In some configurations, the mechanical stopping portion may include the tooth margin and the inclined surface.

[0156] In some configurations, each side strap may include a support housing configured to restrain at least a portion of an elongated plastic member. The support housing may define an internal channel configured to receive the elongated plastic member. The support housing may include an outer collar, an inner collar, and an intermediate portion between the outer collar and the inner collar.

[0157] In some configurations, the support housing may include an internal and an external side. The external side of the intermediate portion of the support housing may include a long opening. The internal side of the support housing may include a continuous wall.

[0158] In some configurations, the outer collar may be configured to contact the contact surface of the hub.

[0159] In some configurations, the outer collar may be configured to contact a mechanical stopper of a long plastic member.

[0160] One aspect of the present disclosure includes a rear portion of a breathing mask headgear that may be formed from a one-piece structure of molten plastic molded into a three-dimensional shape. The one-piece structure of molten plastic may include a one-piece molded upper strap and a one-piece molded lower strap. The one-piece molded upper strap may have a first end, a second end, and a first length between the first end and the second end. The one-piece molded upper strap may include a first curvature configured to approximate or match the shape of the upper portion of the user's head. The one-piece molded lower strap may have a first end, a second end, and a second length between the first end and the second end. The one-piece molded lower strap may include a second curvature configured to approximate or match the shape of the lower or rear portion of the user's head. The first end of the upper strap may together with the first end of the lower strap to form a first joint, and the second end of the upper strap may together with the second end of the lower strap to form a second joint.

[0161] In some configurations, the second length can be greater than the first length.

[0162] In some configurations, the rear portion may include a molded composite structure. The molded composite structure may have at least one fabric layer and at least one plastic layer that are permanently connected to each other.

[0163] In some configurations, the user contact surface of the rear portion may include a flush surface. A flush surface can have little to no variation in thickness.

[0164] In some configurations, the first joint and / or the second joint may include a base and a flex area. The flex area may be located between the base and one of the upper and lower straps.

[0165] In some configurations, the upper and / or lower straps may include relatively stiffer or reinforced portions that are thicker than adjacent portions of the upper and / or lower straps.

[0166] In some configurations, the upper and / or lower straps may include one or more relatively less rigid portions having a thickness less than the adjacent portions of the upper and / or lower straps.

[0167] In some configurations, the first joint and / or the second joint are formed with an initial angle of approximately 60–100 degrees, approximately 70–90 degrees, or approximately 75–80 degrees.

[0168] The aforementioned and other features of this disclosure will become more fully apparent from the following description and the accompanying claims, as interpreted in conjunction with the accompanying drawings. Understanding that these drawings only illustrate some embodiments of this disclosure and are not intended to limit its scope, this disclosure will be described more specifically and in detail through the use of the accompanying drawings. [Brief explanation of the drawing]

[0169] [Figure 1] This is a schematic diagram of a respiratory system configured to supply pressurized and humidified breathing gas to the user via a patient interface. [Figure 2] This is a perspective view of a patient interface assembly positioned on a user. The patient interface assembly includes a nasal mask and an interface in the form of a headgear configuration having a rear portion and side straps on each side of the rear portion. [Figure 3] Figure 2 is a perspective view of the rear portion of the headgear configuration. [Figure 4] This is an enlarged perspective view showing the joint between the upper and lower straps in the rear portion of Figure 3, which is configured to adjust the distance between the upper and lower straps. [Figure 5] This is a rear view of the rear portion of Figure 3. [Figure 6] This is a rear view of an alternative configuration for the rear portion of Figure 3, which is shown in a flat configuration. [Figure 7]Figure 3 is a cross-sectional view of the upper strap at the rear, showing a plastic core and a fabric cover that may be a woven cover. [Figure 8] This is a cross-sectional view of the upper strap inside the molding tool. [Figures 9A-9D] This shows some alternative configurations of the headgear, including several joint shapes and patterns for the knitted fabric cover. [Figure 10] This shows the transition between the inelastic and elastic parts of a knitted fabric covering. [Figure 11] This shows the connection point between the elongated plastic component of the side strap and the rear portion of the headgear. [Figure 12] This is a perspective view of the elongated plastic component of the side strap. [Figure 13] This is a perspective view of the hub portion of the elongated plastic member shown in Figure 12, which has a first wall and a second wall in an open configuration. [Figure 14] This is a perspective view of the hub section in Figure 13, which is in a closed configuration and shows the first wall. [Figure 15] Figure 14 is a perspective view showing the second wall of the hub section. [Figure 16] Figure 14 is a side view of the hub section. [Figure 17] Figure 14 is an end view of the hub section. [Figure 18] Figure 14 is a top view of the first wall of the hub section. [Figure 19] This shows the insertion of a long plastic component into a woven fabric cover before the molding of the plastic core for the rear portion of the headgear configuration. [Figure 20] This shows a long plastic component inside a woven fabric cover after the plastic core has been molded. [Figure 21] This is a perspective view of an alternative hub portion for the elongated plastic component of the side strap. [Figure 22] This is a side view of an alternative joint for the rear headgear section. [Figures 23A-23D] This is a side view of a further alternative connection point for the rear headgear section. [Figure 24] This is a perspective view of an alternative configuration for the rear portion of the headgear assembly. [Figure 25] Figure 24 is a side view of the rear portion of the headgear configuration. [Figure 26] Figure 24 is an enlarged side view showing the joint between the upper strap, lower strap, and side strap at the rear. [Figure 26] Figure 24 is an enlarged side view showing the joint between the upper strap, lower strap, and side strap at the rear. [Figure 27] This is a side view of an alternative configuration for the hub section. [Figure 28] This is a side view of the hub section in Figure 27, and this side is the opposite side of the side shown in Figure 27. [Figure 29] Figure 27 is a side view of the hub section, and this side is perpendicular to the side views in Figures 27 and 28. [Figure 30A] This is a side view of an alternative configuration for a long plastic member and support structure in a minimum length configuration. [Figure 30B] This is a side view of the elongated plastic member and support structure in the maximum length configuration shown in Figure 30A. [Figure 30C] Figure 30A is a perspective view of the user contact side of the elongated plastic member and support structure in the minimum length configuration. [Figure 30D] Figure 30A is a perspective view of the user-contact side of the elongated plastic member and support structure in a partially extended configuration. [Figure 31] Figure 30A is an enlarged perspective view of the mechanical hard stop of the elongated plastic member and support. [Figure 32] Figure 31 is an enlarged perspective view of the mechanical hard stop. [Modes for carrying out the invention]

[0170] Herein, embodiments of the system, components, and methods of assembly and manufacture will be described with reference to the attached diagrams, where the same numbering throughout refers to similar or identical elements. While several embodiments, examples, and descriptions are disclosed below, it will be understood by those skilled in the art that the present invention as described herein extends beyond the specifically disclosed embodiments, examples, and descriptions, and may include other uses of the invention and its obvious modifications and equivalents. The terms used in the descriptions herein are not intended to be limited or restrictive solely because they are used in conjunction with the detailed descriptions of specific embodiments of the invention. Furthermore, embodiments of the invention may include several novel features, and no single feature alone constitutes a desirable characteristic, nor is it essential for the implementation of the invention as described herein.

[0171] In the following explanation, certain terms may be used for reference purposes only and are therefore not intended to be limiting. For example, terms such as “above” and “below” refer to directions within the referenced drawing. Terms such as “front,” “back,” “left,” “right,” “rear,” and “side” describe the orientation and / or position of a component or part of an element within a consistent but arbitrary reference coordinate system, as can be seen by referring to the text and related drawings describing the component or element described. Furthermore, terms such as “first,” “second,” and “third” may be used to describe separate components. Such terms may include the terms specifically mentioned above, their derivatives, and terms of similar meaning.

[0172] System Overview Figure 1 shows an exemplary respiratory therapy system suitable for supplying breathing gas to users of positive airway pressure (PAP) therapy (e.g., continuous positive airway pressure (CPAP) therapy) or non-invasive ventilation (NIV) therapy. The exemplary respiratory therapy system 100 may include a gas source 102, a humidifier 104, a patient interface assembly 150, and a breathing gas circuit 106 connecting the humidifier 104 (or gas source 102) to the patient interface assembly 150. The gas source 102 can supply a constant amount of breathing gas to the humidifier 104. The gas source 102 may include a blower, in which an impeller 112 draws breathing gas, such as ambient air, into the gas source 102 through an inlet 110 of the gas source casing. The rotational speed of the impeller 112 may be adjusted to control the amount of air drawn into the gas source 102 and the amount of breathing gas supplied to the respiratory therapy system 100. The breathing gas may consist of any single or multiple gases that the user of system 100 can breathe.

[0173] The pressure and / or flow rate of the breathing gas exiting the gas source 102 may be adjusted by the controller 114. The controller 114 may adjust the rotational speed of the impeller 112 according to one or more predetermined algorithms and according to one or more user inputs which may be provided via the user input 116.

[0174] The illustrated gas source 102 is an actively controlled flow generator. Other gas sources, such as compressed air cylinders with appropriate pressure or flow control, may also be used to supply breathing gas. The outlet of the gas source 102 may be coupled to a separate humidifier 104. The humidifier 104 may be configured to heat and / or humidify the breathing gas before delivery, for example, before delivery to the user. In some embodiments, the humidifier is integrated with the gas supply unit. The humidifier 104 may include a base 120 and a humidifier chamber 122. The chamber 122 may be configured to hold a humidifying fluid 124, such as water, and may be engaged and disengaged from the humidifier base 120, for example, temporarily or permanently, to allow the chamber 122 to be filled or replaced. The humidifier 104 receives gas from the gas source 102 through the chamber inlet 126. The humidifier base 120 may include a heater, such as a heater plate 130. When the chamber 122 engages with the humidifier base 120, it rests on the heater plate 130. The heater plate 130 dissipates heat, such as heat generated by electrical resistance, to the chamber 122. The chamber 122 preferably has a heat-conducting base to enable efficient transfer of heat generated by the heater plate 130 to the humidifying fluid 124. The controller 114 can also control the supply of electrical energy to the humidifier 104, particularly the heater plate 130, and adjust any function of the humidifier 104, such as the temperature and humidity of the breathing gas supplied to the user.

[0175] The respiratory gas may be supplied to the user via a chamber outlet 132 and a respiratory gas circuit 106 in the form of a conduit that may incorporate a heating or warming element, such as a heater wire, to heat or warm (e.g., keep it hot or warm) the respiratory gas while it is being transported to the patient interface assembly 150. The electrical energy supplied to the heater wire may be controlled by a controller 114. The controller 114 may receive feedback from one or more sensors incorporated into a control network throughout the respiratory therapy system to monitor respiratory gas characteristics, such as but not limited to pressure, flow, temperature, and / or humidity.

[0176] The patient interface assembly 150 connects the user to the respiratory therapy system 100 so that a gas, such as a heated and humidified gas from a humidifier 104, can be delivered to the user's respiratory system. When the gas is delivered to the user's nose and mouth, the respiratory gas can be delivered to the user at or near the optimal temperature and humidity (e.g., 27-37°C, heated and fully saturated with water vapor). By mimicking the conditions in the lungs of a healthy adult (37°C, 44 mg / L humidity), it can help maintain healthy mucociliary function in users with respiratory diseases affecting secretion, and in any patient, humidifying the gas helps maintain comfort and compliance. Several different styles of the patient interface assembly 150, such as those disclosed herein, may be used in the exemplary system 100 or a similar system.

[0177] Interface Assembly Overview Figure 2 shows an exemplary patient interface assembly 150 that may be used in the system 100 of Figure 1. The patient interface assembly 150 generally includes an interface (e.g., a mask) 152 and a headgear configuration ("headgear") 154. The interface 152 is configured to deliver a flow of respiratory gas to the user's airway. The headgear 154 is configured to secure the interface 152 in place on the user.

[0178] The illustrated interface 152 is a mask capable of defining a breathing chamber. In particular, the illustrated interface 152 is a direct nasal mask having a nasal element (e.g., a nasal pillow) configured to deliver a flow of breathing gas directly to the user's nostrils. The mask 152 can also create a seal (e.g., a secondary seal) on the user's face surrounding one or both nostrils and / or the nasal element. However, other suitable interfaces can also be used with the headgear 154, and / or the headgear 154 can be modified for use with different types of interfaces. For example, the interface may be a nasal mask that omits the direct nasal element and defines a sealing surface surrounding one or both of the user's nostrils. The various features, embodiments, and advantages of the patient interface assembly 150 described in the context of the nasal mask 152 will also be understood to be applicable to any other interface configurations, including but not limited to, mouth-nasal masks and full-face masks that seal around the user's nose and mouth, mouth masks that seal around the user's mouth, and nasal pillows or other types of masks that seal below the user's nose.

[0179] The mask 152 may include a frame 156 and a cushion or seal 158. The seal 158 may be directly coupled to the frame 156 or may form part of a cushion module that can be connected to the frame 156. Such a cushion module may include a relatively rigid housing made from a material harder than the material of the seal 158. The relatively rigid housing may be connected to the frame 156. The relatively rigid housing may be removably connected to the frame 156. The relatively rigid housing may engage with part of the frame 156 to incorporate a clip portion that connects the cushion module, and therefore the seal 158, to the frame 156.

[0180] The mask 152 may also include a connecting tube 164 configured to connect the mask 152 to a breathing conduit (e.g., a breathing gas circuit 106). The connecting tube 164 may be supported by any suitable part of the mask 152, such as the frame 156 or a cushion module 160 (e.g., a housing). In the illustrated configuration, the connecting tube 164 is directly connected to the cooperative part of the mask 152. The connecting tube 164 may be permanently or detachably connected to the cooperative part of the mask 152. In other configurations, the mask 152 may be connected to the breathing conduit by a connector that may or may include an elbow.

[0181] The mask 152 may also include an exhaust port or vent to allow exhaled air and excess respiratory gas to exit the breathing chamber of the mask 152. In some configurations, the vent may be a bias flow vent comprising multiple vent holes. The bias flow vent may be located on the mask frame 156 or on other suitable parts of the mask 152, such as a cushion module or connecting tube 164. In some configurations, the bias flow vent may include a diffuser, which covers multiple vent holes to diffuse the exhaled gas and reduce the velocity of the exhaled gas and / or the noise generated by the exhaled gas. The diffuser may be removable from the mask 152 for cleaning or replacement, or may be permanently attached to a part of the mask 152 by a method such as lap molding, in which the diffuser material is placed in a mold and then a suitable plastic material (e.g., polycarbonate) is injected into the mold to create a single structure. The diffuser material may be lap-molded directly onto the frame 156. In other embodiments, the diffuser material may be lap-molded onto a clip. The clip has an engaging portion for engaging with a complementary engaging feature on another part of the mask 152, which is for attaching the clip (and associated diffusion material) to that part of the mask 152.

[0182] The headgear 154 is coupled to the mask 152. The headgear 154 may be coupled to the frame 156 of the mask 152. Preferably, the frame 156 or the mask 152 includes a single headgear mount on each side of the frame 156 or the mask 152. In the illustrated configuration, the headgear 154 includes headgear straps provided on each side of the user's head, the headgear straps branching at a position generally above the user's ears to form an upper strap portion and a lower strap portion. The straps on each side may be separate from each other, or the headgear 154 may form a closed loop structure surrounding the user's head and have surface connections that connect to the frame 156 or the mask 152. The headgear 154 will be described in more detail below.

[0183] headgear Figures 2 to 20 show an example of the headgear 154 described above. In the illustrated configuration, the headgear 154 generally has a front portion 200 and a rear portion 210. The front portion 200 is configured to connect to the mask 152 and extends between the mask 152 and the rear portion 210 along each side of the user's head. The rear portion 210 is configured to engage with the rear portion of the user's head.

[0184] The illustrated front portion 200 includes straps 212 that connect to the mask 152 via appropriate connectors, such as clips, on each side of the interface assembly 150. In the illustrated configuration, the straps 212 on each side of the interface assembly 150 are separate from each other and connect to the mask 152 separately. The front straps 212 may be mirror images of each other. Thus, unless otherwise specified herein, the details described herein with respect to one strap 212 may be considered to apply to the other strap 212 as well, except in a symmetrical state.

[0185] Each strap 212 extends from the mask 152, across the user's cheek, to the joint 220 with the rear portion 210. Because the straps 212 extend generally along the sides of the user's head, they may be referred to herein as “side straps.” In the illustrated configuration, each side strap 212 extends slightly upward from the end closer to the mask 152 towards the end closer to the joint 220. Each side strap 212 extends towards or to a position above the user's ears. In some configurations, the rear end of each side strap 212 may be directly above or above the line of the user's ears and slightly in front of or slightly behind the user's ears.

[0186] As described above, the headgear 154 branches on each side, transitioning from a front section 200 having a single strap 212 on each side to a rear section 210 having two strap sections. In particular, the rear section 210 of the headgear 154 includes a first or upper strap section or strap 230 and a second or lower strap section or strap 232. Each of the upper strap 230 and lower strap 232 extends around the back of the user's head and is configured to connect to the side straps 212. For example, as shown in Figure 2, the upper strap 230 extends upward from the joint 220, and the lower strap 232 extends downward from the joint 220. In other words, the upper strap 230 and lower strap 232 are spaced apart from each other.

[0187] In some configurations, the rear portion 210 of the headgear 154 is configured to allow the upper strap 230 and the lower strap 232 to move relative to each other. For example, the rear portion 210 may be configured to allow the upper strap 230 and the lower strap 232 to move to allow adjustment of an angle 240 (Figure 3) defined between the upper strap 230 and the lower strap 232. The angle 240 may be defined between the respective centerlines (e.g., geometric centerlines) of the upper strap 230 and the lower strap 232.

[0188] The relative positions of the upper strap 230 and the lower strap 232 can also be described by the separation distance 242 (Figure 5) between the straps 230 and 232. The separation distance 242 can be defined as the distance between any two positions on the upper strap 230 and the lower strap 232 at a given relative position of the upper strap 230 and the lower strap 232. For example, the upper strap 230 may have an outer or upper edge 244 and an inner or lower edge 246. The lower strap 232 may have an inner or upper edge 250 and an outer or lower edge 252. The separation distance 242 can be defined between the edges 244, 246 of the upper strap 230 and the edges 250, 252 of the lower strap 232. For convenience, in this specification, the separation distance 242 is expressed as the straight-line distance between the lower edge 246 of the upper strap 230 and the upper edge 250 of the lower strap 232, taken along the centerline or vertical center plane that penetrates the headgear 154 in the longitudinal direction.

[0189] The rear portion 210 of the headgear 154 may define a specific angle 240 and / or separation distance 242 in a loosened or neutral position. The loosened or neutral position may be the position of the rear portion 210 that has been molded or defined by a molding tool in a molded embodiment. The loosened or neutral position may be the position of the rear portion 210 where no external force is applied that would deform the rear portion 210. Such an angle 240 or separation distance 242 may be referred to as the static angle 240 or static separation distance 242.

[0190] As described above, the rear section 210 may be configured to allow relative movement between the upper strap 230 and the lower strap 232 in order to allow adjustment of the angle 240 and / or separation distance 242. The rear section 210 may be configured to allow relative movement between the upper strap 230 and the lower strap 232, resulting in an increase of the angle 240 and / or separation distance 242 relative to an initial angle 240 or separation distance 242, which may be a stationary angle 240 or stationary separation distance 242. The rear section 210 may be configured to allow relative movement between the upper strap 230 and the lower strap 232, resulting in a decrease of the angle 240 and / or separation distance 242 relative to an initial angle 240 or separation distance 242, which may be a stationary angle 240 or stationary separation distance 242. The rear section 210 may be configured to allow relative movement between the upper strap 230 and the lower strap 232, resulting in either an increase or decrease of the angle 240 and / or the separation distance 242 relative to an initial angle 240 or separation distance 242, which may be a stationary angle 240 or a stationary separation distance 242. Such a configuration allows the rear section 210 to be adapted to various head shapes and / or user preferences. Furthermore, when the external force is removed from the rear section 210, the rear section 210 may be configured to return to or from the initial angle 240 or separation distance 242, which may be a stationary angle 240 or a stationary separation distance 242. That is, the rear section 210 may have an elastic restoring force as a result of the choice of material, shape, or combination thereof. Furthermore, the stationary separation distance 242 is preferably greater than zero so that some space or gap is provided between the straps 230 and 232. This may suggest to the user that straps 230 and 232 are designed to provide separation.

[0191] In some configurations, the rear portion 210 is configured such that the upper strap 230 can be adjusted to pass over the top of the user's head from one side to the other of the headgear 154. The upper strap 230 may be positioned over the user's parietal bone. In some configurations, the upper strap 230 may be adjustable to be positioned over the user's frontal bone and / or over the user's occipital bone. The rear portion 210 is configured such that the lower strap 232 can be adjusted to pass over the back of the user's head from one side to the other of the headgear 154. The lower strap 232 may be positioned over the user's occipital bone. In some configurations, the lower strap 232 may be adjustable to be positioned over the user's parietal bone.

[0192] In some configurations, the rear portion 210 is formed to have a stationary angle 240 of approximately 60–100 degrees, approximately 70–90 degrees, or approximately 75–80 degrees. In some configurations, the rear portion 210 is formed to have a stationary angle 240 of approximately 77 degrees. In some configurations, the rear portion 210 may be adjustable to a minimum angle 240 of less than approximately 20 degrees, less than approximately 10 degrees, or approximately 0 degrees, or until the separation distance 242 is zero. In some configurations, the rear portion 210 may be adjustable to a maximum angle 240 of at least approximately 90 degrees, at least approximately 120 degrees, at least approximately 135 degrees, at least approximately 150 degrees, or at least approximately 170 degrees. In some configurations, the rear portion 210 may be adjustable to a maximum angle 240 of approximately 180 degrees or more.

[0193] At least a portion of the headgear 154 may be fabricated as a molded composite structure having at least one fabric layer and at least one plastic layer permanently connected to each other. In some configurations, at least the rear portion 210 is fabricated as such a molded composite structure. In the illustrated configuration, as shown in Figure 7, the rear portion 210, which includes the upper strap 230, the lower strap 232 and the joint 220, is a molded composite structure having two fabric layers (e.g., an inner or internal layer 260 and an outer or external layer 262) and a plastic core 270 located between the fabric layers 260 and 262. The rear portion 210 may be formed as a single structure by applying molten plastic to the space between the fabric layers 260 and 262 in a mold and curing the molten plastic to form a plastic core 270 with a shape corresponding to the shape of the mold hole. The fabric layers 260 and 262 may be separate from each other and may be joined or connected via the plastic core 270 (for example, a tubular structure surrounding the plastic core 270). The composite structure of the rear portion 210 will be described in more detail below.

[0194] Part or all of the headgear 154 may be semi-rigid. In the illustrated configuration, one of the side straps 212, the joint 220, the upper strap 230, and the lower strap 232, any combination thereof, or all of them may be semi-rigid. As used herein, semi-rigid means that the semi-rigid portion of the headgear 154 can generally maintain its shape under its own weight, but has some flexibility to allow the semi-rigid portion to bend around the user's head. In some configurations, the semi-rigid portion of the headgear 154 is more rigid in one direction and less rigid in a second direction. For example, the semi-rigid portion of the headgear 154 may be substantially rigid in the vertical direction or along the user's face, and relatively flexible in the horizontal direction or toward and away from the user.

[0195] Figures 3 to 6 show the plastic core 270 of the rear portion 210 of the headgear 154 without the fabric layers 260 and 262. In the illustrated configuration, the plastic core 270 of the rear portion 210 is manufactured as a single, integrated body portion containing the plastic material. That is, the joint 220, the upper strap 230, and the lower strap 232 are manufactured as a single, integrated structure. The upper strap 230 has a first end 280 and a second end 282. A first length, or upper strap length 284, is defined between the first end 280 and the second end 282. Similarly, the lower strap 232 has a first end 290 and a second end 292. A second length, or lower strap length 294, is defined between the first end 290 and the second end 292. In the illustrated configuration, the lower strap length 294 is greater than the upper strap length 284. However, in other configurations, the upper strap length 284 may be greater than the lower strap length 294, or the two lengths 284 and 294 may be equal or substantially equal.

[0196] As shown in Figure 5, the upper strap 230 also defines a width 300. Similarly, the lower strap 232 defines a width 302. One or both of the widths 300, 302 may vary along the respective lengths 284, 294 of the straps 230, 232. For example, the widths 300, 302 at or near the ends 280, 282, 290, 292 of the straps 230, 232 may be smaller than the widths 300, 302 at or near the central portions 310, 312 of the upper strap 230 and the lower strap 232, respectively. In the illustrated configuration, the width 302 of the lower strap 232 is greater than the width 300 of the upper strap 230. At corresponding positions (e.g., end sections 280, 282, 290, 292 or central sections 310, 312), the width 302 of the lower strap 232 may be greater than the width 300 of the upper strap 230. Alternatively or additionally, the width 302 along the entire length of the lower strap 232 may be greater than the width 300 along the entire length of the upper strap 230. In other words, the minimum width 302 of the lower strap 232 may be greater than the maximum width 300 of the upper strap 230. The difference between the width 300 of the upper strap 230 and the width 302 of the lower strap 232 can help the user distinguish between the straps 230, 232, and thus properly orient the rear section 210 and / or headgear 154. In some configurations, the width 300 of the upper strap 230 is approximately 15 mm, and the width 302 of the lower strap 232 is approximately 17.5 mm. These widths 300 and 302 may be the minimum, maximum, or average width of the straps 230 and 232.

[0197] As described above, the rear portion 210 of the headgear 154 is configured to allow relative movement between the upper strap 230 and the lower strap 232, and to allow adjustment of the angle 240 or separation distance 242 between the straps 230 and 232. In some configurations, most or all of the relative movement is provided by joints 220 between the ends 280, 282, 290, 292 of the straps 230 and 232. Each joint 220 may be configured to allow or facilitate relative movement between the straps 230 and 232. The joints 220 may allow or facilitate the movement of one or both of the upper strap 230 and the lower strap 232 relative to the joint 220. In the illustrated configurations, the joints 220 are mirror images of each other. Therefore, for convenience, this specification describes one joint 220. Unless otherwise specified, the description of one joint 220 may apply equally to the other joint 220, except in symmetrical configurations.

[0198] Referring to Figure 4, the joint 220 includes a base portion 350 which may be an end portion of the joint 220 (e.g., a front end portion). The joint 220 also includes a transition region 352 between the base portion 350 and one or both of the upper strap 230 and the lower strap 232. In the illustrated configuration, each of the upper strap 230 and the lower strap 232 is joined to the base portion 350 of the joint 220 by the transition region 352 (e.g., a first transition region and a second transition region). The transition regions 352 are discrete from each other and separated by the base portion 350. However, in other configurations, the transition regions 352 may be connected to each other, or a single transition region 352 may join both the upper strap 230 and the lower strap 232 to the base portion 350.

[0199] Each transition region 352 is configured to allow movement (e.g., angular motion) of each strap 230, 232 relative to the base portion 350 of the joint 220. In some configurations, the transition region 352 also allows torsional motion of each strap 230, 232, thereby allowing the straps 230, 232 to better conform to the head shape of a particular user. The transition region 352 may enable or facilitate this movement by any suitable mechanism, such as the size and / or shape of the transition region 352, the choice of material, or a combination thereof. In the illustrated configuration, the transition region 352 is a localized area of ​​reduced size (e.g., width and / or thickness) relative to the base portion 350 and one or both of the associated straps 230, 232.

[0200] The structure of the joint 220 and straps 230, 232 adjacent to and including the transition region 352 forms a flex region 354 that enables or facilitates the above-mentioned movement. The flex region 354 includes the transition region 352 and may also include a portion of the base portion 350 of the joint 220 and a portion of the straps 230, 232. That is, the bending movement of the upper strap 230 and / or lower strap 232 relative to the base portion 350 may result in some bending or deformation of a portion of the base portion 350 and / or a portion of the straps 230, 232 adjacent to the transition region 352. The flex region 354 is generally shown by the dashed area shown in Figure 3. The flex region 354 may be substantially the same size as the transition region 352 compared to the significantly larger structure of the rear portion 210, such as the joint 220 and the base portion 350 of the straps 230, 232. Therefore, the dimensions and relative size of the transition area 352 described herein may be equivalent to those of the flex area 354.

[0201] The structure of the joint 220 and straps 230, 232 adjacent to and including the transition region 352 and / or the flex region 354 may form a living hinge structure. A living hinge, which may be called a deflection joint, deflection bearing, or bending bearing, is a flexible segment or portion of a material that joins two relatively stiffer segments or portions. The hinge is flexible and bendable, allowing movement of the attached segments or portions. A living hinge is typically made from the same material as the two stiffer portions that the living hinge connects. This is the case with the integrated rear portion 210 disclosed herein. A living hinge is typically thinned or machined so that the stiff portions can be bent along the hinge line. A living hinge does not include a defined pivot structure. The low wear and minimal friction of the living hinge are advantageous for the adjustable rear section 210, which may be subjected to many adjustment cycles and may be used by people with weak hand strength and / or low dexterity. The living hinge may be substantially similar in size to the transition area 352 and / or flex area 354 compared to the significantly larger structure of the rear section 210, such as the joint 220 and the base section 350 of the straps 230, 232. Thus, the dimensions and relative sizes described herein with respect to the transition area 352 and / or flex area 354 may also apply equally to the living hinge.

[0202] The base portion 350 defines a maximum possible width 360. Each transition region 352 also defines a minimum possible width 362. The width 362 of the transition region 352 may be smaller than the width 360 of the base portion 350. The width 362 of the transition region 352 may be smaller than the widths 300 and 302 of the associated straps 230 and 232 to which the transition region 352 is joined. The width 362 of the transition region 352 may be smaller than both the width 360 of the base portion 350 and the widths 300 and 302 of the associated straps 230 and 232.

[0203] The reduced width 362 of the transition region 352 facilitates the rotational movement of the straps 230, 232 and, as described above, allows for adjustment of the relative positions of the straps 230, 232. In some configurations, the width 362 of the transition region 352 is less than half or less than one-third of the width 300, 302 of each of the upper straps 230 or lower straps 232 to which the transition region 352 is joined. In some configurations, the width 362 of the transition region 352 is less than about 10 mm, less than about 8 mm, or less than about 7 mm. In some configurations, the width 362 of the transition region 352 is about 3 mm to 7 mm, or about 5 mm.

[0204] The transition region 352 defines a length 364. The length 364 may be the length of the width reduction portion of the joint 220 between the base portion 350 and the associated straps 230, 232. As described above, preferably, the transition region 352 is a localized area of ​​reduced size. Therefore, the size of the transition region 352 (e.g., length 364) is smaller than the size of the associated straps 230, 232 (e.g., lengths 284, 294). In some configurations, the length 364 of the transition region 352 is smaller than the width 360 of the base portion 350 and / or one width 300, 302 of each of the upper strap 230 or lower strap 232 to which the transition region 352 is joined. In some configurations, the length 364 of the transition region 352 is smaller than about two-thirds or one-half of the one width 300, 302 of each of the upper strap 230 or lower strap 232 to which the transition region 352 is joined. In some configurations, the length 364 of the transition region 352 is less than approximately 10 mm, less than approximately 8 mm, or less than approximately 7 mm. In some configurations, the length 364 of the transition region 352 is approximately 3 mm to 7 mm, or approximately 5 mm.

[0205] Each transition region 352 is at least partially defined by a slot 370 formed by the plastic core 270 of the rear portion 210. In the illustrated configuration, the slots 370 are connected to one another. The slots 370 are also connected to the space between the upper strap 230 and the lower strap 232 (between the lower edge 246 and the upper edge 250). In the illustrated configuration, the slots 370 cooperate to define a substantially arcuate or partially annular opening. The slots 370 are also partially defined by a rounded projection 372 of the base portion 350. In some configurations, the slots 370 are similar in size and / or shape to one another. In some configurations, the joint 220 may be symmetrical or substantially symmetrical about an axis 374 (Figure 3) passing between the joint 220 and the upper strap 230 and the lower strap 232. Each slot 370 may define a width 376 (e.g., maximum width). The width 376 of slot 370 may be smaller than the width 360 of base portion 350 and / or the widths 300, 302 of each of the upper strap 230 or lower strap 232 located adjacent to slot 370.

[0206] In the illustrated configuration, each of the upper strap 230 and the lower strap 232 includes a relatively stiffer or reinforced portion, referred to herein as the main strap portion 380. Preferably, one or both of the upper strap 230 and the lower strap 232 also include one or more relatively less stiff portions, referred herein as the flange portion 382. The main strap portion 380 is in the form of a thicker rib compared to the flange portion 382. The main strap portion 380 may be configured to accommodate most or all of the tensions applied to the rear portion 210 of the headgear 154 as a result of normal use, such as blow-off forces and / or tensile forces. The flange portion 382 may be configured to distribute the force applied to the user's head over a wider area compared to the case of the main strap portion 380 alone. The flange portion 382 may also be more flexible than the main strap portion 380 to give the rear portion 210 of the headgear 154 variable bending characteristics along the width and / or length of the straps 230, 232.

[0207] Referring to Figure 7, the main strap portion 380 may define a first thickness 390, and the flange portion 382 may define a second thickness 392. The second thickness 392 may be smaller than the first thickness 390. In other words, the first thickness 390 may be larger than the second thickness 392. In some configurations, the first thickness 390 may be about 1.5 to 5 mm, about 2 to 3 mm, or about 2 to 2.5 mm. The second thickness 392 may be about 1 to 2.5 mm, about 1 to 2 mm, or about 1 to 1.5 mm. The relative thicknesses 390, 392 may include any value or relative ratio that falls within the above range or dimensions. The thicknesses 390, 392 may include or may omit the cover layers 260, 262. The dimensions of the cover layers 260, 262 will be further described below.

[0208] In the illustrated configuration, the main strap portion 380 extends along the entire or substantially entire length 284, 294 of one or both of the upper strap 230 and the lower strap 232. Such a configuration ensures that the rear portion 210 of the headgear 154 has sufficient strength or rigidity to adapt to the forces expected during use. For example, as shown in Figure 4, the base portion 350 of the joint 220 may have the same or similar thickness as the thickness 390 of the main strap portion 380. The main strap portion 380 and / or the base portion 350 may be rounded or tapered toward the edges to avoid edges that may reduce comfort or give the user an uncomfortable appearance, as shown in Figures 4 and 7. As illustrated, the base portion 350 may also be rounded or tapered toward the slot 370.

[0209] In some configurations, the main strap portion 380 is provided along one or both edges of the straps 230, 232. In some configurations, the main strap portion 380 defines the entirety of one or both edges of the straps 230, 232. In the illustrated configuration, the main strap portion 380 defines the entirety of the upper edge 244 of the upper strap 230. However, the main strap portion 380 may define less than the entirety of the upper edge 244. In the illustrated configuration, the main strap portion 380 defines the entirety of the lower edge 252 of the lower strap 232. However, the main strap portion 380 may define less than the entirety of the lower edge 252. Such configurations encourage twisting within the straps 230, 232, resulting in the upper edge of the upper strap and the lower edge of the lower strap being positioned in front of or forward of the lower edge of the upper strap and the upper edge of the lower strap, respectively. Such orientation of the straps 230, 232 fits or adapts to most head shapes. In other configurations, these configurations can be reversed, and the main strap portion 380 may define part or all of the lower edge portion 246 of the upper strap 230 and / or the upper edge portion 250 of the lower strap 232.

[0210] Preferably, the flange portion 382 extends along most of the lengths 284, 294 of the straps 230, 232. In some configurations, the flange portion 382 extends along only a portion of the lengths 284, 294. In the illustrated configuration, the flange portion 382 is provided on each side of the central portions 310, 312 of the upper and lower straps 230, 232, respectively. The flange portion 382 of each strap extends along at least about half, at least about two-thirds, or about two-thirds of the lengths 284, 294 of the straps 230, 232. The flange portion 382 may be configured to extend substantially along each side of the user's head during use.

[0211] As shown in Figure 5, the central portions 310, 312 of each illustrated strap 230, 232 are generally defined by the main strap portion 380. In other words, the main strap portion 380 extends to the full width 300, 302 of the straps 230, 232 within part or all of the central portions 310, 312. In the illustrated configuration, the main strap portion 380 tapers in width at each side of the central portions 310, 312, and similarly, the flange portion 382 tapers in width from the side or end of the rear portion 210 toward the central portions 310, 312.

[0212] In some configurations, the main strap portion 380, or the main strap portion 380 and flange 382 together define the entire width 300, 302 of the straps 230, 232 at any position along the lengths 284, 294 of the straps 230, 232. As shown above, in the illustrated configuration, the main strap portion 380 defines the entire width 300, 302 of the central portions 310, 312 of the straps 230, 232. Such a configuration may allow the straps 230, 232 to maintain a relatively large arc in a neutral position to facilitate attachment and removal by the user. Furthermore, the load on the central portions 310, 312 (the rear portion when attached) is greater than the load on the end portions (the side portions when attached). Therefore, greater torsional and / or bending resistance in the central portions 310, 312 is desirable.

[0213] In some configurations, the length 400 of the central portion 310 or main strap portion 380 of the upper strap 230 may differ from the length 402 of the central portion 310 or main strap portion 380 of the lower strap 232. As shown in Figure 5, the length 400 of the upper strap 230 is smaller than the length 402 of the lower strap 232. Thus, the lower strap 232 can have a larger arc (e.g., a larger diameter) than the upper strap 230, which makes it easier for the user to distinguish between straps 203 and 232 and / or allows for a better fit to the head shape of a typical user. In some configurations, the length 400 may be about 50mm to 100mm, about 60mm to 90mm, about 70mm to 80mm, or about 75mm. The length 402 may be about 75mm to 125mm, about 85mm to 115mm, about 95mm to 105mm, or about 100mm. In other configurations, this configuration can be reversed, and length 400 may be greater than length 402, or lengths 400 and 402 may be the same. Lengths 400 and 402 may be defined as the maximum, minimum, or average length of the main strap section 380 within the central sections 310 and 312.

[0214] As described above, the rear portion 210 may be made from or include a molded plastic structure. In the illustrated configuration, the rear portion 210 includes a one-piece plastic structure (e.g., a plastic core 270). The plastic core 270 may be molded into a three-dimensional shape, for example, as shown in Figures 3 to 5. The three-dimensional molded shape may be the same as or similar to the neutral shape of the rear portion 210. In other configurations, the plastic core 270 may be molded into a different shape, such as a flat shape. A flat plastic core 270 may be formed into a predetermined shape by the user, for example, when the headgear 154 is applied to the user's head. In other configurations, the flat plastic core 270 may be formed into a three-dimensional shape during the manufacturing process or before use. For example, as shown in Figure 6, one or both of the upper strap 230 or lower strap 232 (upper strap 230 in the illustrated example) may be split or divided into two parts when molded or formed. The ends of the divided straps 230, 232 may then be joined by an appropriate joining configuration or process, such as adhesive bonding. Also, as described above, the rear portion 210 may also include one or more fabric layers 260, 262. The ends of the divided straps 230, 232 may also be joined whole or partially by the fabric layers 260, 262.

[0215] The plastic core 270 can be made from any suitable material or combination of materials. In some configurations, the plastic core 270 can be made from a thermoplastic elastomer (TPE) material such as polyether block amide (PEBA). An example of such a material is sold under the brand name Pebax® by Arkema SA in Colombes, France. In particular, the material may be Pebax® 2533. In some configurations, the material may have a Shore hardness of about 10–40 Shore D, about 20–30 Shore D, or about 22–27 Shore D. Such a material can be used to obtain a plastic core 270 that has some elasticity or allows for a certain amount of stretching. The elasticity of the plastic core 270 can be modified by fabric layers 260, 262 or other coverings, as will be further described below. Alternatively, the plastic core 270 can be made from a silicone material that can provide a desired amount of flexibility. Low Shore stiffness, such as within the above range, gives the rear portion 210 of the headgear 154 a "stiff fabric" feel. In other words, the rear portion 210 of the headgear 154 is perceived by the user as a stiff fabric strap rather than a plastic strap with a fabric covering. Advantageously, the disclosed rear portion 210 has the shape memory of plastic, while still providing the characteristics of a typical fabric headgear strap, such as soft texture, tactile feel, visual appeal, and flexibility. The upper and lower straps 230, 232 are flexible, but the structure of the rear portion 210 of the headgear 154 maintains its shape without the straps 230, 232 bending or tangling like a typical fabric strap. Such a configuration enhances the usability and convenience of the headgear 154.

[0216] Referring to Figures 7 and 8, as described above, the plastic core 270 may be covered by one or more fabric layers, such as layers 260, 262. In some configurations, only one side of the plastic core 270 (e.g., the inner side or the outer side) is covered by a fabric layer. In the illustrated configuration, both the inner and outer sides of the plastic core 270 are covered by fabric layers 260, 262. As described above, the fabric layers 260, 262 may be separate from each other (and may be joined by the plastic core) or may be directly joined to each other. As described above and further described below herein, the fabric layers 260, 262 may be formed as a single structure (e.g., a tubular structure such as a knitted tubular structure).

[0217] When formed, the fabric layers 260, 262 may be positioned adjacent to each other or joined along the edges of the plastic core 270 between the inner and outer sides (e.g., the upper and lower edges during use). The fabric layers 260, 262 may be configured to have protruding edges 410 at the upper and lower edges, respectively. The protruding edges 410 may be defined by the length of the fabric layers 260, 262 extending beyond the plastic core 270. The protruding edges 410 can provide increased padding along the edges of the plastic core 270 compared to designs without protruding edges 410, thereby providing the user with improved comfort and / or a more comfortable appearance. In some configurations, the protruding edges 410 may have a width 412 of approximately 0.5 mm to 3 mm, approximately 0.75 mm to 2 mm, or approximately 1 mm. In some configurations, the protruding edge 410 may have a thickness 414 of approximately 0.3 mm to 2 mm, approximately 0.4 mm to 1 mm, approximately 0.4 mm, or approximately 0.3 mm. The thickness of each layer 260, 262 may be approximately 0.2 mm to 1 mm, approximately 0.2 mm to 0.5 mm, or approximately 0.2 mm. Thus, in some configurations, the width and / or thickness of the protruding edge 410 may be greater than the thickness of the individual layers 260, 262. The protruding edge 410 may also include an air (or other gas) space between layer 260 and layer 262 to provide additional comfort. In some configurations, the protruding edge 410 is provided along the upper strap 230 and lower strap 232 of the rear portion 210. The protruding edge 410 may also be provided on the outer edge of the joint 220. However, preferably, the protruding edge 410 is omitted from the inner edge of the joint 220 defined by the slot 370. Such a configuration can increase flexibility, or at least avoid the obstruction of the flexibility of the upper strap 230 and / or lower strap 232 by further lumps that would have been present if the protruding edge 410 were provided along the inner edge of the joint 220.

[0218] Figure 8 shows a mold tool 420 that may be used to form the rear portion 210 of the headgear 154. As described above, the fabric layers 260, 262 may be placed within a portion or half 424, 426 of the mold tool 420. The mold tool 420 includes a stopper 428 that forms the protruding edges 410 of the fabric layers 260, 262. The stopper 428 may define a space of size and shape that accommodates the protruding edges 410, but is small enough that little or no plastic material can fit inside. Thus, the plastic core 270 may have a shape with rounded upper and lower edges defined by the shape of the portion of the mold tool 420 adjacent to the stopper 428, as shown in the figure. To form a plastic core 270 and permanently bond the fabric layers 260 and 262 to the plastic core 270, molten plastic material is introduced into the mold hole 422 of the mold tool 420 between the fabric layers 260 and 262 and allowed to cure.

[0219] As shown in Figure 2, the fabric layers 260, 262 may also extend along part or all of the front portion 200 of the headgear 154 or the side straps 212. It may be desirable that the side straps 212 be able to vary in length to allow the headgear 154 to fit a variety of users and / or to facilitate putting on and taking off the headgear 154. In some configurations, the headgear 154 is configured to provide easy adjustment to a size suitable for individual users.

[0220] In some configurations, the mask assembly 150 may use one or more directional locks 430 (Figures 2 and 12) that provide different resistances to different directions of motion between the mask 152 and the headgear 154. For example, a directional lock 430 can provide a first resistance to the motion of the mask 152 and headgear 154 in a first direction away from each other, thereby increasing the perimeter or circumference of the closed loop defined by the mask 152 and headgear 154. A directional lock 430 can provide a second resistance to the motion of the mask 152 and headgear 154 in a second direction toward each other, thereby decreasing the perimeter or circumference of the closed loop defined by the mask 152 and headgear 154. The first resistance force is greater than the second resistance force.

[0221] This configuration provides relatively low resistance to a decrease in the closed-loop circumference for easy attachment to the user, and relatively high resistance to an increase in the closed-loop circumference to prevent or stop an increase in the closed-loop circumference in response to normal or expected forces during use, such as blowing force and / or tensile force. Preferably, the first resistance force is configured to be overcome by the manual force applied by the user to enable attachment or removal of the mask assembly 150. Furthermore, the second resistance force is low enough that a relatively small elastic force is provided by a suitable elastic member (or spring or biasing mechanism) to automatically move the mask 152 and headgear 154 toward each other, thereby reducing the closed-loop circumference to or to a size suitable for a particular user.

[0222] During use, the user can position the mask 152 in place on their face and pull the rear portion 210 of the headgear 154, overcoming a first resistance force provided by the directional lock 430, thereby increasing the closed-loop circumference so that the rear portion 210 of the headgear 154 can be positioned over the rear portion of the user's head. The user can release the rear portion 210 of the headgear 154, decreasing the closed-loop circumference with appropriate elastic members and overcoming a second resistance force provided by the directional lock 430, thereby moving the mask assembly 150 toward or to a suitable closed-loop circumference for a particular user. Once treatment is initiated, the directional lock 430 prevents or restricts the increase in the closed-loop circumference in accordance with the normal or expected force during use. When treatment is complete, the user can grasp the rear portion 210 of the headgear 154, overcoming the first resistance force and increasing the closed-loop circumference to remove the mask assembly 150.

[0223] In some configurations, as described above, the side straps 212 provide a change in the closed-loop circumference of the mask assembly 150. Furthermore, the side straps 212, particularly the fabric layers 260, 262, provide an elastic force that tends to decrease the closed-loop circumference against a second resistive force provided by the directional locks 430. In some configurations, the directional locks 430 are located on each side of the mask assembly 150. The directional locks 430 may be supported by the mask 152 and may interact with a portion of the associated side straps 212. Thus, the first resistive force can prevent the extension of the associated side straps 212, and the second resistive force can prevent the shortening of the associated side straps 212. The side straps 212 can extend between the mask 152 and the rear portion 210 of the headgear 154 and can be connected to the mask 152 and the rear portion 210 of the headgear 154, and an elastic or biasing force can be applied to the side straps which tends to shorten them, thereby reducing the closed-loop circumference or moving the mask 154 toward the rear portion 210 of the headgear.

[0224] In some configurations, the fabric layers 260, 262 cooperate to form a cover 440 for both the front portion 200 and the rear portion 210 of the headgear 154. The cover 440 may be a single-piece structure. In some configurations, the portion 442 of the cover 440 located on the rear portion 210 of the headgear 154 is inelastic or relatively inelastic, and the portion 444 of the cover 440 located on the front portion 200 of the headgear 154 or the side straps 212 is elastic or relatively elastic. As described above, the cover 440 may be formed by a knitted structure. The advantage of a knitted structure is that the relatively inelastic portion 442 and the relatively elastic portion 444 can be formed as a single piece or a single-piece structure.

[0225] As described above, the plastic core 270 may be made from a material that has some elasticity or allows for some degree of stretching. The elasticity or stretchability of the plastic core 270 can be modified by the non-elastic material, the relatively non-elastic material, or the generally non-elastic properties of the rear portion 442 of the cover 440. As a result of combining the elastic or stretchable material of the core 270 with the non-elastic material of the cover 440, the rear portion 210 may be relatively non-elastic or substantially non-elastic, but may provide a favorable level of flexibility. A permanent connection between the cover 440 and the plastic core 270 can promote or enhance a relatively high level of flexibility that rarely exceeds an acceptable amount of stretching. The resulting rear portion 210 may be considered non-stretchable or substantially non-stretchable. When used herein, a substantially non-stretchable headgear component will not exceed an acceptable amount of stretching and can maintain the interface in a predetermined position on the user's face in an appropriate position for delivering the desired treatment.

[0226] In some configurations, the woven tubular cover 440 may be formed by a suitable knitting process using suitable materials, such as the processes and materials described herein. The woven cover 440 may be formed as a single component including one or more of the side straps 212, upper straps 230, and lower straps 232. In other words, the woven cover 440 may be formed by knitting a single component including branching from the side straps 212 to the upper and lower straps 230, 232 via the joints 220.

[0227] The knitted cover 440 can be knitted to a shape that approximates or substantially matches the final shape of the headgear 154, which is partially determined by the mold holes of the mold tool 420. With such a configuration, the stitch structure and knitting direction will roughly or substantially match the shape of the plastic core 270, which is determined by the mold holes of the mold tool 420. The resulting rear portion 210 of the headgear 154 will have a knitted edge that matches the curvature of the plastic core 270, which can reduce material deposition and / or accumulation compared to fabric coverings made from flat sheet material.

[0228] Referring to Figures 1 and 9A to 10, as described above, different parts 442, 444 of the cover 440 may be made of different materials or combinations of different materials. For example, in the illustrated configuration, the rear or non-elastic part 442 of the knitted cover 440 is made using a first material 450 (e.g., the meshed fiber in Figure 10), such as a first yarn or filament type. In some configurations, the first material 450 is or includes nylon (e.g., textured nylon). Textured nylon provides bulk and stability on the back of the user's head, as well as a comfortable texture for the user. In the illustrated configuration, the front part 200 or side straps 212 use a second material 452 (e.g., the unmeshed fiber in Figure 10), such as a second yarn or filament type. In some configurations, the second material 452 is or includes elastane material (e.g., Lycra). In some configurations, the second material 452 is nylon-wound (for example, double-wound nylon) elastane.

[0229] As shown in Figure 10, the transition between the rear section 442 and the front section 444 may include both the first material 450 and the second material 452. In the transition, both the first material 450 and the second material 452 are woven over a certain number of rows. Such a process is called reinforcing weave. The purpose of the transition and reinforcing weave is to provide reinforcement and strength to the joint between the inelastic section 442 and the elastic section 444. In some configurations, the reinforcing weave may extend over a large portion or the entirety of one of the upper strap 230 or the lower strap 232. Such configurations may provide different textures between the straps 230, 232 and may help the user distinguish between the upper strap 230 and the lower strap 232.

[0230] In some configurations, the cover 440 can be knitted laterally, starting with one side strap 212, progressing to the upper and lower straps 230, 232 of the rear section 210, and ending with the other side strap 212. Alternatively, the cover 440 can be knitted from top to bottom or bottom to top. At the transition between the first side strap 212 and the rear section 201, the aforementioned reinforcing knitting technique can be applied to one of the upper straps 230 or lower straps 232, allowing a transition from the second material 452 to the first material 450. In one of the upper straps 230 or lower straps 232, if the yarn or filament of the second material 452 of the elastic section 444 is cut, additional yarn or filament of the first material 450 can be introduced and knitted to form the other of the upper strap 230 and lower strap 232. Once the rear section 210 is knitted, the reinforcing knitting technique can be repeated, and the second side strap 212 can be formed from the second material 452.

[0231] Referring to Figures 2 and 9A-9D, the materials used to fabricate the cover 440 can vary in order to provide the headgear 154 with variations in color, pattern and / or texture to facilitate distinction between different parts of the headgear 154 (e.g., between straps 212, 230, and 232), or to provide visual or textural interest, or both. As shown in Figures 2 and 9A-9D, a first color may be provided to part or all of the rear portion 210 of the headgear 154, and a second different color may be provided to part or all of the front portion 200. As shown in Figure 9D, the transition between the front portion 200 and the rear portion 210 may include further colors or designs, such as stripes or bands, to function as a step transition. Furthermore, either or both of the front portion 200 and the rear portion 210 may include multiple colors, patterns, or textures.

[0232] Figures 9A–9C also show possible variations in the shape of the joint 220. For example, the slot 370 (Figure 4) can take different shapes to provide a different shape to one or more of the base portion 350, the transition region 352, or the ends 280, 282, 290, 292 of the straps 230, 232. Exemplary shapes of the slot 370 may include triangles, quadrilaterals (e.g., rhombic, rhombus (Figure 9C), square, trapezoid), pentagons (Figure 9A), other polygons, round or circular (Figure 9B), and combinations thereof. Further examples of alternative joints 220 are disclosed herein with reference to Figures 23A–23D.

[0233] As described above, the mask assembly 150 uses one or more directional locks 430 that provide different resistances for different directions of motion between the mask 152 and the headgear 154. The side straps 212 provide a change in the closed-loop circumference of the mask assembly 150 and also provide an elastic force that tends to reduce the closed-loop circumference against the second resistance force provided by the directional locks 430. In the illustrated configuration, the directional locks 430 are located on each side of the mask assembly 150 and interact with the corresponding portions of the side straps 212. As shown in Figures 11 and 12, the headgear 154 includes an elongated plastic member 460 coupled to the rear portion 210 of the headgear 154, extending along the side straps 212 and engaging with the directional locks 430 (Figure 11). In the illustrated configuration, the elongated plastic member 460 extends within the cover 440 or between layers 260 and 262 of the cover 440.

[0234] The illustrated elongated plastic member 460 includes a first portion 462 and a second portion 464. The first portion 462 is a relatively thicker portion, and the second portion 464 is a relatively thinner portion. The relative difference in thickness between the first portion 462 and the second portion 464 may be in one or both cross-sectional dimensions. However, in the illustrated configuration, the elongated plastic member 460 has a constant thickness, and the width (or height in the orientation of use) between the first portion 462 and the second portion 464 varies. The first portion 462 can provide some rigidity to at least a portion of the side strap 212 compared to at least the cover 440 alone. The second portion 464 may connect to the directional lock 430. In the illustrated configuration, the elongated plastic member 460 has a rectangular or substantially rectangular cross-sectional shape.

[0235] As shown in Figure 11, a second portion 464 of the elongated plastic member 460 engages with the directional lock 430. The directional lock 430 can be any suitable configuration to produce the different resistances described above for different directions of relative motion between the elongated plastic member 460 and the directional lock 430. In some configurations, the directional lock 430 may include one or more locking elements 470. The locking elements 470 may be movable (e.g., pivotable) within the support or housing 472. The second portion 464 of the elongated plastic member 460 passes through the housing 472 and the holes of the locking elements 470. The movement of the elongated plastic member 460 relative to the directional lock 430 can move the locking elements 470 between a first position in which the directional lock 430 exhibits a first resistance force and a second position in which the directional lock 430 exhibits a second resistance force.

[0236] The end of the elongated plastic member 460 opposite the second portion 464 includes a hub 466. The hub 466 facilitates the connection of the elongated plastic member 460 to the rear portion 210 of the headgear 154. The hub 466 can engage with the rear portion 210. In some configurations, the hub 466 or the adjacent portion of the hub 466 and the first portion 462 of the elongated plastic member 460 may be joined to the rear portion 210 by an overlap-molded joint, as shown in Figure 11. In particular, the plastic core 270 of the rear portion 210 may be overlap-molded on or over the adjacent portion of the hub 466 and the first portion 462 of the elongated plastic member 460. The hub 466 may be located within the base portion 350 of the joint 222. In some configurations, the length 467 of the hub 466 may be about 5mm to 10mm, about 6mm to 9mm, about 7mm to 8mm, or about 7.5mm.

[0237] The hub 466 may generally be configured to facilitate the molding of the plastic core 270 or the lamination molding of the plastic core 270 onto a long plastic member 460. Referring to Figures 13–18, the hub 466 may include an inlet or port 480 configured to receive the molten plastic material forming the plastic core 270. In some configurations, the diameter of the port 480 may be about 1 mm to 5 mm, 2 mm to 4 mm, or about 3 mm. The hub 466 may include an internal channel or flow path 482. The internal channel or flow path 482 connects to the port 480 and opens to the outer surface of the hub 466. In the illustrated configuration, the flow path 482 extends in the width direction throughout the hub 466. In some configurations, the length 481 of the flow path 482 may be about 1 mm to 5 mm, about 2 mm to 4 mm, or about 2.5 mm. In some configurations, the thickness or height 483 of the channel 482 may be approximately 0.5 mm to 3 mm, approximately 1 mm to 2 mm, or approximately 1 mm. The molten plastic material received in the port 480 can pass through the channel 482 and exit from the hub 466 to form the plastic core 270.

[0238] In the illustrated configuration, the hub 466 includes a first wall or cap 490 and a second wall or cap 492. The first cap 490 may be an external cap 490 located on the outside of the headgear 154 during use, and the second cap 492 may be an internal cap 492 located on the inside of the headgear 154 during use. The external cap 490 and the internal cap 492 can be formed separately or in separate configurations and joined together to form the hub 466. For example, the external cap 490 may be connected to a first portion 462 of an elongated plastic member 460. The internal cap 492 may be connected to the external cap 490 by a hinge connection 494. However, this configuration can be reversed.

[0239] As described above, the outer cap 490 and the inner cap 492 can be connected to form a hub 466. For example, the outer cap 490 and the inner cap 492 may include cooperative connection or alignment features to facilitate the alignment or connection of the caps 490 and 492. In the illustrated configuration, the outer cap 490 may include one or more (e.g., a pair) alignment or connection holes 500, and the inner cap 492 may include one or more (e.g., a pair) alignment or connection pins 502 that are received within the connection holes 500. However, this configuration can also be reversed.

[0240] The hub 466 can be molded or manufactured with the outer cap 490 and inner cap 492 positioned on the same plane as shown in Figure 13. After molding, the inner cap 492 can be connected to the outer cap 490 by bending the hinge 494 to create the hub 466 as shown in Figures 14 to 18. In the illustrated configuration, each of the outer cap 490 and the inner cap 492 defines a portion of the depth of the flow channel 482. However, in other configurations, either the outer cap 490 or the inner cap 492 may define the entire depth of the flow channel 482.

[0241] Referring to Figures 19 and 20, the elongated plastic member 460 is inserted into the cover 440 before being laminated with the plastic core 270. In Figures 19 and 20, for clarity, portions of the side straps 212 are cut off (indicated by dashed lines). In particular, the elongated plastic member 460 may be inserted into the open front end of the side strap portion 444 of the cover 440, as indicated by the arrow in Figure 19. The portion of the cover 440 surrounding the joint 220 of the plastic core 270 may include a hole 510 having the same size and / or shape as the port 480 of the hub 466, or slightly smaller in size and / or shape than the port 480 of the hub 466. In other configurations, the hole 510 may be slightly larger in size and / or shape than the port 480. In other configurations, the holes 510 can be omitted, and the molten plastic material can pass directly through the woven cover 440, or through gaps between the threads of the woven cover 440, etc., by a part of a molding tool (e.g., an injection needle). The holes 510 can be created by or after the knitting process. The elongated plastic member 460 is positioned inside the cover 440 such that the port 480 is aligned with the holes 510, as shown in Figure 20.

[0242] The cover 220 and the elongated plastic member 460 may be placed within a mold tool, such as the mold tool 420 shown in Figure 8. The elongated plastic member 460 may include features to assist in positioning or maintaining the proper position of the elongated plastic member 460 within the mold tool 420. For example, a first portion 462 of the elongated plastic member 460 adjacent to the hub 466 may include one or more alignment features or alignment holes 512. One or more alignment features or alignment holes 512 cooperate with appropriate structures (e.g., pins or protrusions) within the mold tool 420 to fix the elongated plastic member 460 in the desired position within the mold hole 422.

[0243] A mold tool 420 can define an inlet or runner (not shown) of the mold hole 422, which is aligned with the hole 510 and the port 480 of the hub 466. Molten plastic material forming the plastic core 270 is introduced into the mold hole 422 through the inlet or runner, passes through the hole 510, the port 480 and the flow path 482, and enters the space between layers 260 and 262 of the rear portion 442 of the cover 440, thereby forming the plastic core 270 inside the cover 440. An internal side cap 392 located opposite the port 480 can prevent or block molten plastic injected directly from the inlet or runner from penetrating the woven cover. Figure 20 shows the rear portion 210 of the headgear with the plastic core 270 formed inside and permanently connected to the rear portion 442 of the cover 440. A suitable connector (not shown) for connecting to the frame 156 of the mask 152 may be connected to the free end of the side strap portion 444 of the cover 440 by any suitable configuration or process, such as lap molding, which may be carried out in the same or different process as the formation of the plastic core 270.

[0244] Figure 21 shows an alternative embodiment of the elongated plastic member 460 having an alternative hub 466. In other respects, the elongated plastic member 460 may be the same as or similar to the elongated plastic member 460 described above. The hub 466 in Figure 21 includes a single wall 490 which may generally correspond to the outer cap 490 of the previous embodiment. Under at least some conditions, it may not be necessary to have an inner cap 492 or other structure opposite the port 480 for blocking or redirecting the flow of molten plastic. In such situations, a simplified hub 466 configuration can be used.

[0245] Figure 22 shows an alternative joint 220 including a single circular slot 370. The circular slot 370 forms a transition region 352 between the base portion 350 of the joint 220 and each of the upper straps 230 and lower straps 232. In the illustrated configuration, the circular slot 370 may have a rounded edge 371 that forms the transition region 352. The transition region 352 can provide a rear portion 210 of the headgear 154 having the same or similar adjustment characteristics as in the embodiments described above.

[0246] Figures 23A to 23D show additional further alternative joints 220 that may provide the same or similar adjustment characteristics as those of the embodiments described above. The joint 220 in Figure 23A includes a substantially triangular slot 370 that creates a transition area 352 and a flex area 354 between the base portion 350 of the joint 220 and each of the upper straps 230 and lower straps 232. The joint 220 in Figure 23B includes a substantially rhomboid slot 370 that creates a transition area 352 and a flex area 354 between the base portion 350 of the joint 220 and each of the upper straps 230 and lower straps 232. The joint 220 in Figure 23C includes a substantially pentagonal slot 370 that creates a transition area 352 and a flex area 354 between the base portion 350 of the joint 220 and each of the upper straps 230 and lower straps 232. The joint 220 in Figure 23D includes a substantially circular slot 370 that creates a transition area 352 and a flex area 354 between the base 350 of the joint 220 and each of the upper straps 230 and lower straps 232. In the joint 220 in Figure 23d, the transition between the transition area 352 and the straps 230, 232 is more gradual.

[0247] Another configuration of the rear portion 210A of the headgear 154 is shown in Figures 24 to 26. Figures 24 to 26 show configurations of the rear portion 210A similar to the rear portion 210 described with reference to Figures 2 to 20, and may have similar features. Reference numbers of the same, substantially the same, or corresponding features may share the same first three digits. Any component disclosed in any configuration herein may be used in any other configuration.

[0248] As described above, at least the rear portion 210A can be manufactured as a molded composite structure. In the illustrated configuration, as shown in Figures 24 to 26, the rear portion 210A, including the upper strap 230A, the lower strap 232A and the joint 220A, may be a molded composite structure having a fabric cover 440A which may include at least one fabric layer (e.g., two fabric layers), and a plastic core 270A located within the fabric cover 440A. In Figures 24 to 26, the internal plastic core 270A and the external fabric cover 440A are shown as solid lines, but the plastic core 270A is understood to be located inside the fabric cover 440A, as in the previous configuration. The rear portion 210A can be formed as a single structure by applying molten plastic to the space within the fabric cover 440A in a mold and curing the molten plastic to form a plastic core 270A with a shape corresponding to the shape of the mold hole. The two fabric layers of the fabric cover 440A may be separate from each other and may be joined or connected via the plastic core 270A (for example, a tubular structure surrounding the plastic core 270A). The composite structure of the rear portion 210A will be described in more detail below.

[0249] In the illustrated configuration, the plastic core 270A can be molded into a three-dimensional shape using a pre-formed, contoured mold tool that forms a three-dimensional plastic core 270A with curves configured to approximate or match the shape of the user's head, for example. This three-dimensional tool allows the plastic core 270A to be molded into a three-dimensional shape such that different parts of the rear section 210A are formed continuously with respect to each other. For example, the upper strap 230A and the lower strap 232A are continuous rather than being formed from two or more parts that need to be connected or combined. The continuous straps 230A, 232A allow the rear section 210A to have a smooth, continuous surface so that the rear section 210A may be more comfortable during use. In some configurations, one or more of the multiple straps 212A, 230A, 232A may be configured to be inelastic such that the straps 212A, 230A, 232A do not have the ability to stretch or bend, or have limited ability to do so. In some configurations, the user contact surface of the rear portion 210A may have a flush surface with little change in thickness to enhance user comfort.

[0250] In some configurations, the upper strap 230A and the lower strap 232A may have different lengths and / or widths from each other to better adapt to a typical user's head shape and / or to facilitate proper positioning of the straps 230A, 232A over the user's head. As described above and as shown in Figures 24 and 25, the upper strap 230A may include a first length or upper strap length 284A that may differ from the second length or lower strap length 294A of the lower strap 232A. In the illustrated configurations, the lower strap length 294A may be greater than the upper strap length 284A. In some configurations, the lower strap length 294A may be approximately 150mm to 350mm, approximately 175mm to 325mm, approximately 200mm to 300mm, approximately 225mm to 275mm, or approximately 254mm. In some configurations, the upper strap length 284A may be approximately 140mm-340mm, 160mm-320mm, 180mm-300mm, 200mm-280mm, 220mm-260mm, or 241mm. In some configurations, the ratio of the lower strap length 294A to the upper strap length 284A may be approximately 1.0-1.3, 1.1-1.2, or 1.054. In other configurations, the upper strap length 284A may be greater than the lower strap length 294A, or the two lengths 284A and 294A may be equal or substantially equal.

[0251] In some configurations, the width 300A of the upper strap 230A and the width 302A of the lower strap 232A can be equal or substantially equal. In some configurations, the widths 300A and 302A can be approximately 10mm to 20mm, approximately 12mm to 18mm, approximately 14mm to 18mm, or approximately 14mm. These widths 300A and 302A can be the minimum, maximum, or average width of the straps 230A and 232A. However, in other configurations, the widths 300A and 302A of the straps 230A and 232A can differ from each other. That is, the width 300A of the upper strap 230A can be smaller or larger than the width 302A of the lower strap 232A.

[0252] In some configurations, the rear section 210A may include different sizes to accommodate users with different head circumferences. For example, the rear section 210A may include two or more of the following sizes: extra small (XS), small (S), medium (M), large (L), and extra-large (XL). The length and / or width of the upper and lower straps 230A, 232A of the extra-large rear section 210A may be greater than the length and / or width of the upper and lower straps 230A, 232A of the extra-small rear section.

[0253] In some configurations, the upper strap 230A and / or the lower strap 232A may include a relatively stiffer or reinforced portion (i.e., main strap portion 380A) which may have a greater thickness than adjacent portions of the straps 230A and 232A. In these configurations, the upper strap 230A and / or the lower strap 232A may include one or more relatively less stiff portions (i.e., flange portions 382A) which may have a thinner thickness than the main strap portion 380A. As shown in Figures 24 and 25, the central portion 312A of the lower strap 232A may be defined by the main strap portion 380A. The flange portions 382A may be located on both sides of the main strap portion 380A. The length of the main strap portion 380A may be about 40mm to 60mm, about 45mm to 55mm, or about 53mm. In some configurations, only one of the straps 230A, 232A includes a relatively stiffer or reinforced portion (i.e., the main strap portion 380A). In the illustrated configuration, only the lower strap 232A includes a relatively stiffer or reinforced portion (i.e., the main strap portion 380A). This configuration provides tactile and visual orientation features to help the user determine the correct orientation of the rear portion 210A during use. However, in other configurations, the arrangement can be reversed so that only the upper strap 230A includes a relatively stiffer or reinforced portion (i.e., the main strap portion 380A).

[0254] Figure 26 shows an enlarged view of the joint 220A between the upper strap 230A, the lower strap 232A, and the side strap 212A. In the illustrated configuration, the joint 220A may include a substantially U-shaped slot 370A defined by a plastic core 270A, creating transition areas 352A, 352B and flex areas 354A, 354B (Figure 25) between the base portion 350A of the joint 220A and one of the upper strap 230A and the lower strap 232A. In some configurations, the width 362A of the first transition area 352A of the upper strap 230A may differ from the width 362B of the transition area 352B of the lower strap 232A. For example, the width 362A of the first transition area 352A may be smaller or larger than the width 362B of the second transition area 352B. In some configurations, the relative widths of the transition regions 352A and 352B relate to or are proportional to the relative volumes of each strap 230A and 232A defined by the plastic core 270A, and this difference may relate to differences in length and / or thickness. That is, straps 230A and 232A with a larger volume of plastic material may have transition regions 352A and 352B with larger widths 362A and 362B. In some configurations, the width 362A of the first transition region 352A may be about 3.5 mm, and the width 362B of the second transition region 352B may be about 4 mm. During manufacturing, the larger width 362B of the second transition region 352B may facilitate a greater flow of molten plastic material from the port 480A. This may be necessary to form a longer lower strap 232A with a main strap portion 380A.

[0255] In some configurations, as shown in Figure 26, the woven cover 440A may have a constant or nearly constant width along its length. The constant or nearly constant width of the woven cover 440A can reduce the time required for the weaving process. Furthermore, as described above, the transition regions 352A, 352B of the plastic core 270A may have a reduced width 362A, 362B (Figure 25) relative to the base portion 350A and / or upper strap 230A and / or lower strap 232A of the joint 220A. In some configurations, the woven cover 440A may have a slight taper in the transition regions 352A, 352B so that the woven cover 440A has a smooth curve along the transition regions 352A, 352B. For example, the reduction in the width of the woven cover 440A from its widest point to its narrowest point may be about 10% to 30% or about 15% to 25%. During manufacturing, the width of the knitted cover 440A may be tapered, for example, by tightening the knit of the knitted cover 440A toward the joint 220A where the upper strap 230A and the lower strap 232A come into contact, in order to minimize the length of the knitted cover 440A at the base of the joint 220A.

[0256] In some configurations, the knitted cover 440A may form fabric flaps 602, 604 adjacent to the transition regions 352A, 352B, respectively. Each fabric flap 602, 604 is a region of the knitted cover 440A that is not supported by the plastic core 270A and is wider than the width of the corresponding straps 230A, 232A. In some configurations, the cover 440A may include internal protruding edges 410A (i.e., the lower edges of the upper strap 230A and the upper edges of the lower strap 232A) and external protruding edges 410B (i.e., the upper edges of the upper strap 230A and the lower edges of the lower strap 232A). In some configurations, the fabric flaps 602, 604 may be formed using the same or similar process as the protruding edges 410A, 410B. In some configurations, the fabric flaps 602, 604 may be continuous with the internal protruding edge 410A. In some configurations, the width 606 of the fabric flaps 602, 604 may be greater than the width of the protruding edges 410A, 410B. Preferably, each fabric flap 602, 604 is significantly wider than either one of the protruding edges 410A, 410B, and in some configurations, it may be at least twice as wide as either one of the protruding edges 410A, 410B. In some configurations, each fabric flap 602, 604 is at least about one-quarter, at least about one-third, or at least about one-half of the width of the corresponding strap 230A, 232A at any position corresponding to the fabric flap 602, 604, or the maximum width of the corresponding strap 230A, 232A. For example, the width 606 of the fabric flaps 602, 604 may be about 2mm to 7mm, about 3mm to 6mm, about 4mm to 6mm, or about 5.8mm. In some configurations, the fabric flaps 602, 604 may have a length 608 (for example, between the joint 220 and the protruding edge 410) of approximately 15mm to 40mm, approximately 20mm to 35mm, approximately 25mm to 30mm, or approximately 26mm. In some configurations, the width 606 of the fabric flaps 602, 604 may vary along the length 608 of the fabric flaps 602, 604 so that the knitted cover 440A transitions smoothly from one part to another (for example, from the fabric flaps 602, 604 to the protruding edge 410A).

[0257] Another configuration of hub 466A is shown in Figures 27–29. Figures 27–29 show a configuration of hub 466A that is similar to hub 466, which may have similar features to those described with reference to Figures 11–21. Reference numbers for the same, substantially the same, or corresponding features may share the same first three digits. Any component disclosed in any configuration herein may be used in any other configuration.

[0258] Referring to Figures 27-29, the hub 466A may include a substantially rectangular shape. For example, the lengths 712, 716 of the hub 466A may be greater than the width 717 of the hub 466A. In some configurations, the lengths 712, 716 of the hub 466A may be approximately 10mm-15mm, approximately 12mm-14mm, or approximately 13mm. In some configurations, the width 717 of the hub 466A may be approximately 5mm-10mm, approximately 7mm-8mm, or approximately 9mm. In some configurations, the thickness 718 of the hub 466A may be approximately 1mm-5mm, approximately 2mm-4mm, or approximately 2mm. In some configurations, the diameter of the port 480A may be approximately 1mm-5mm, approximately 2mm-4mm, or approximately 2mm. As shown in the illustrated configuration, port 480A may be positioned on the hub 466A such that port 480A is aligned with the center of or near the center of junction 220A (Figure 26). In some configurations, port 480 may be positioned elsewhere on the hub 466.

[0259] In some configurations, the hub 466A may include a first side portion 702 and a second side portion 704. The hub 466A can be used in any orientation of the product when in use. In some configurations, the first side portion 702 of the hub 466A can be oriented relatively downward or to the same side as the lower strap 232A, and the second side portion 702 of the hub 466A can be oriented relatively upward or to the same side as the upper strap 234A, and vice versa. In other words, the first side portion 702 can be on one side of the longitudinal axis 706 of the elongated plastic member 460A, and the second side portion 704 can be on the other side. In some configurations, the vertical orientation of the hub 466A (relative to the orientations shown in Figures 27 and 28) can be reversed or inverted from one side to the other of the headgear 154. This configuration allows a single elongated plastic member 460A, including the hub 466A, to be used on each side of the headgear 154, thereby reducing manufacturing and storage costs and simplifying the manufacturing process compared to a design that uses different hubs 466A on each side of the headgear 154.

[0260] In some configurations, the hub 466A may be asymmetrical with respect to one or more axes or in one or more directions of the hub 466A. For example, the hub 466A may be asymmetrical along or around the longitudinal axis 706 of the elongated plastic member 460A. For example, the first and second side portions 702, 704 may have widths 710, 712 and lengths 714, 716, respectively. The first width 710 and first length 712 of the first side portion 702 may be greater than the second width 714 and second length 716 of the second side portion 704. Alternatively, the second width 714 and second length 716 may be greater than the first width 710 and first length 712, or may be the same as or substantially the same as the first width 710 and first length 712. In some configurations, the first width 710 may be about 2mm to 5mm, about 3mm to 4mm, or about 3.25mm. In some configurations, the first length 712 may be approximately 10mm to 15mm, approximately 12mm to 13mm, or approximately 13mm. In some configurations, the second width 714 may be approximately 1mm to 4mm, approximately 2mm to 3mm, or approximately 2.25mm. In some configurations, the second length 716 may be approximately 10mm to 15mm, approximately 11mm to 14mm, or approximately 11.25mm. In some configurations, the hub may be asymmetrical about the vertical axis of the hub 466A extending through the center of the lengths 712, 716 of the first or second side portions 702, 704. In some configurations, the hub may be asymmetrical about both the longitudinal axis 706 of the first portion 462A of the elongated plastic member 460A and the vertical axis of the hub 466A.

[0261] As shown in the illustrated configuration, the second side portion 704 may include a directional notch 708 and / or the first side portion 702 may include a directional key 709. In some configurations, the hub 466A may include a first end 701 and a second end 703 which can be integrated with or attached to a first portion 462A of an elongated plastic member 460A. In the illustrated configuration, the first end 701 of the hub 466A may be continuous along the first and second side portions 702, 704, respectively. The second end 703 of the hub 466A may also include an offset 707 such that the second end 711 of the first side portion 702 is offset from the second end 713 of the second side portion 704. In some configurations, the second end 703 of the hub 466A may be continuous, while the first end 701 of the hub 466A may include an offset. In some configurations, the ends 701, 703 may be continuous or include an offset. During manufacturing, the hub 466A and the first portion 462A of the elongated plastic member 460A may be placed into a mold hole of the three-dimensional mold tool described above or the mold tool 420 described in relation to Figure 8 in order to lap-molde the hub 466A onto the plastic core 270A. This lap-molding process may be the same as or similar to the lap-molding process described elsewhere in this disclosure. The asymmetry of the directional notch 708, the directional key 709 and / or the hub 466A can reduce the risk of the elongated plastic member 460A being assembled incorrectly. For example, the asymmetry of the hub 466A can prevent incorrect orientation with respect to the two orientations shown in Figures 27 and 28. Furthermore, as described above, the orientation of the hub 466A may differ on each side of the headgear 154.

[0262] Another configuration of the side strap 212A of the headgear 154 is shown in Figures 30A to 32. The difference between the side strap 212A in this configuration and the previously described configuration is the addition of a support structure 728, which will be described in detail below.

[0263] In some configurations, the support structure 728 can be attached to the rear portion 210A of the headgear 154. For example, referring to Figures 30A to 30D, the elongated plastic member 460A can be engaged with the support structure 728, supported by the support structure 728, or at least partially restrained by the support structure 728. For example, the support structure 728 may include a rigid or semi-rigid material (e.g., plastic) and have an elongated body with a channel extending through its length. The elongated plastic member 460A can pass through the channel, and the support structure 728 can restrain at least a portion of the elongated plastic member 460A. In some configurations, the support structure 728 may include an inner collar 724 and an outer collar 720. When mounted, the inner collar 724 may be positioned inside the support structure 728, and the outer collar 720 may be positioned outside the support structure 728. As detailed below, the user can move the elongated plastic member 460A within the support structure 728 to change the length of the side strap 212A.

[0264] In some configurations, the woven cover 440A can enclose the support structure 728. In some configurations, the woven cover 440A can cover a portion (e.g., one side) of the elongated plastic member 460A and / or the support structure 728. In some configurations, the support structure 728 may include a rectangular cross-section and an outer side 730 facing away from the user's face and an inner side (not shown) facing the user's face. The inner side of the support structure 728 may have a solid wall, while the outer side 730 of the support structure 728 may have an opening 734 extending for part of the length of the support structure 728. For example, the opening 734 may extend for the length between the inner collar 720 and the outer collar 724.

[0265] Referring to Figures 28 to 30D, in some configurations, the outer surface 736 of the hub 466A may be aligned in the thickness direction with or continuous with the outer surface 738 of the first portion 462A of the elongated plastic member 460A. In some configurations, as shown in Figure 29, the inner surface 740 of the hub 466A may be offset from the inner surface 742 of the first portion 462A of the elongated plastic member 460A. The offset between the two inner surfaces 740, 742 can create a height step, thereby creating a contact wall 746 to which the support structure 728 can abut, as will be detailed below. In some configurations, at least a portion of the hub 466A is not covered by the overlap-molded post-molded portion 210. For example, as shown in Figure 26, the outer portion of the hub 466A may be overlap-molded with the joint 220A so that the contact wall 746 can extend beyond the inner wall of the joint 220A. In some configurations, the external surfaces 736 and 738 may be offset from each other, while the internal surfaces 740 and 742 may be continuous. In some configurations, both the external surfaces 736 and 738 and the internal surfaces 740 and 742 may be offset from each other or continuous.

[0266] As described above and with reference to Figures 31 and 32, the elongated plastic member 460A may include a relatively wider first portion 462A and a relatively narrower second portion 464A. In some configurations, the first portion 462A may have a width of about 3.5 mm, while the second portion 464A may have a width of about 0.86 mm. In some configurations, the elongated plastic member 460A may include a transition region 748 between the first portion 462A and the second portion 464A, tapering from the wider first portion 462A to the narrower second portion 464A. In one example, the length of the first portion 462A including the transition region 748 may be about 100 mm, and the length of the second portion 464A may be about 95 mm. However, these lengths may vary depending on other features of the directional lock 430.

[0267] In the illustrated configuration, the elongated plastic member 460A may include a mechanical stop feature 726 configured to engage with the support structure 728. Figures 30A and 30C show the side strap 212A in a fully retracted configuration where the side strap 212A is at its minimum length and / or the outer collar 720 of the support structure 728 abuts against the hub 466A. Figure 30D shows the side strap 212A in a partially extended configuration where the side strap 212A is at a partially extended length. Figures 30B and 31 show the side strap 212A in a fully extended configuration where the side strap 212A is at its maximum length and / or the mechanical stop feature 726 abuts against the outer collar 720 of the support structure 728. In some configurations, the mechanical stop feature 726 may be located between the first portion 462A and the second portion 464A. The mechanical stop feature 726 may be located in or near the transition region 748. In some configurations, the mechanical stopping feature 726 may have a rigid configuration and be a projection, protrusion, projection, bar, or rib projecting radially outward from the elongated plastic member 460A. In the illustrated example, the mechanical stopping feature 726 may have an inclined edge 727 and a toothed edge 725. During manufacturing, the second portion 464A of the elongated plastic member 460A can be passed through the collars 720, 724 of the support structure 728. The inclined edge 727 may also allow the first portion 462A to pass through the outer collar 720.

[0268] In some configurations, the outer collar 720 of the support structure 728 may be configured to engage with the elongated plastic member 460A and restrain the elongated plastic member 460A. For example, in the fully retracted configuration shown in Figure 30A, the outer wall of the outer collar 720 abuts against the contact wall 746 (Figure 29) and the first side portion 702 of the hub 466A, preventing the elongated plastic member 460A from being pulled further in the retraction direction through the directional lock 430. This contact may form an inelastic limit on the amount by which the elongated plastic member 460A can extend through the directional lock 430. In other words, this limit may not depend on the elastic properties of the elastic portion 444 of the cover 440 (Figure 2). Furthermore, in this position, the side strap 212A may be at its minimum length, and the headgear may be at its minimum headgear size. In some configurations, as shown in Figure 30B, the elongated plastic member 460A can move in the extensional direction by overcoming a first resistance of the directional lock 430 until the toothed edge 725 of the stop 726 abuts against the inner wall of the outer collar 720. This abutment can limit the amount by which the elongated plastic member 460A can be pulled away from the directional lock 430. Furthermore, at this position, the side strap 212A may be at its maximum length, and the headgear may be at its maximum headgear size. Examples of elongated members (e.g., filaments), support structures, and mechanical stopping features having generally similar structures and used in similar applications are disclosed in International Publication No. 2020 / 096467, which is incorporated in whole herein by reference.

[0269] In the illustrated configuration, both sides of the outer color 720 define the minimum and maximum positions of the elongate plastic member 460A (by interaction with the hub 466A and the mechanical stop 726). However, other configurations are possible where the interaction, engagement, or physical contact between any suitable surface of the elongate plastic member 460A and the support structure 728 defines the minimum and maximum positions or ranges. For example, if the elongate plastic member 460A is slid into these colors 720, 724 such that the abutment between the colors 720, 724 and the mechanical stop 726 is configured to limit the movement of the elongate plastic member 460A, the mechanical stop 726 can be configured to abut the colors 720, 724. For example, the mechanical stop 726 can be configured to abut the outer wall of the inner color 724 in the fully retracted position to prevent the elongate plastic member 460A from being further pulled in the retraction direction through the directional lock 430.

[0270] Conclusion It should be emphasized that many changes and modifications can be made to the embodiments described herein, and the elements thereof should be understood as being, among other things, acceptable examples. All such modifications and changes are intended to be included within the scope of the present disclosure and be protected by the following claims. Further, any of the steps described herein can be performed in a different order than simultaneously or as the steps are ordered herein. Further, as will be apparent, the features and characteristics of the specific embodiments disclosed herein can be combined in different ways to form further embodiments, all of which are within the scope of the present disclosure.

[0271] Conditional language used herein, such as, among others, "can", "could", "might", "may", "e.g.", etc., is generally intended to convey that a particular embodiment includes a particular feature, element, and / or state and that other embodiments do not, unless otherwise expressly stated or understood within the context in which it is used. Thus, such conditional language is not generally intended to imply that a feature, element, and / or state is necessarily required in one or more embodiments, or that one or more embodiments necessarily include logic for determining whether these features, elements, and / or states are included, with or without the input or indication of the inventor, or whether they are implemented in any particular embodiment.

[0272] Furthermore, the following terms may be used herein. The singular forms "a", "an", and "the" include the indicated objects in the plural unless the context clearly dictates otherwise. Thus, for example, a reference to an item includes a reference to one or more items. The term "ones" refers to one, two or more, and generally applies to some or all selections of a quantity. The term "plurality" refers to two or more items. The terms "about" or "approximately" mean that a quantity, dimension, size, form, parameter, shape, and other characteristics need not be exact and may be approximated and / or increased or decreased as desired, reflecting acceptable tolerances, conversion efficiencies, rounding, measurement errors, and other elements well known to those skilled in the art. The term "substantially" means that although the recited characteristics, parameters, or values need not be achieved exactly, deviations or variations, including, for example, tolerances, measurement errors, measurement accuracy limits, and other elements well known to those skilled in the art, may occur in an amount that does not preclude the effect that the characteristic is intended to provide.

[0273] In this specification, numerical data may be expressed or presented in range format. Such range format is used solely for convenience and conciseness, and should therefore be interpreted flexibly to include the numbers explicitly listed as the limits of the range, as well as to include all individual numbers or subranges contained within that range, as if each number and subrange were explicitly listed. For example, the numerical range "approximately 1 to 5" should be interpreted to include not only the explicitly listed values ​​of approximately 1 to approximately 5, but also the individual values ​​and subranges within the indicated range. Therefore, this numerical range includes individual values ​​such as 2, 3, and 4, as well as subranges such as "approximately 1 to approximately 3," "approximately 2 to approximately 4," and "approximately 3 to approximately 5," "1 to 3," "2 to 4," and "3 to 5." This same principle applies to ranges representing only one number (e.g., "greater than approximately 1"), regardless of the breadth of the range or the characteristics described. For convenience, multiple items may be presented within a common list. However, these lists should be interpreted as if each element of the list were individually identified as a distinct and unique element. Therefore, no individual element of such a list should be interpreted, without the opposite indication, as a de facto equivalent of any other element of the same list solely on the basis that they are presented within a common group. Furthermore, where the terms “and” and “or” are used with a list of items, they should be interpreted broadly in that one or more of the enumerated items may be used alone or in combination with other enumerated items. The term “alternatively,” unless explicitly indicated in the context, refers to selecting one of two or more options, and is not intended to limit the selection to only the enumerated options, or to only one of the enumerated options at a time.

Claims

1. A rear portion of a breathing mask headgear, which includes an integrated main body portion including a three-dimensionally molded molten plastic integral structure, The aforementioned rear portion is configured to engage with the rear portion of the user's head. The aforementioned integrated main body portion is An upper strap having a first end, a second end, a length between the first end and the second end, and a width, A lower strap having a first end, a second end, a length between the first end and the second end, and a width, It includes a first joint between the first end of the upper strap and the first end of the lower strap, and a second joint between the second end of the upper strap and the second end of the lower strap, Each joint includes a base portion and a living hinge between the base portion and one of the upper strap and the lower strap. The upper strap and the lower strap extend from the joint and around the back of the user's head. Each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, wherein the main strap portion extends along the entire length of the strap from the first joint to the second joint, and the at least one flange portion extends along most of the length of the strap. The at least one flange portion of the upper strap extends along the lower edge of the upper strap facing the lower strap in the width direction, The at least one flange portion of the lower strap extends along the upper edge of the lower strap facing the upper strap in the width direction, The living hinge is defined by a slot, the slot opening on the extension of the edge formed by the at least one flange portion of the upper strap and the at least one flange portion of the lower strap, The living hinge is a flexible portion that connects one of the upper strap and the lower strap to the base portion, and is made of the same material as the upper strap, the lower strap, and the base portion, and is less rigid than the upper strap, the lower strap, and the base portion. The rear portion of a breathing mask headgear, wherein the upper strap, the lower strap, the first joint, and the second joint are semi-rigid.

2. The rear portion of the breathing mask headgear according to claim 1, wherein the joint is symmetrical with respect to an axis passing between the joint and the upper strap and the lower strap.

3. The rear portion of the breathing mask headgear according to claim 1 or 2, wherein the at least one flange portion extends along only a portion of the length of the strap.

4. The rear portion of the breathing mask headgear according to any one of claims 1 to 3, wherein the main strap portion or the main strap portion and the flange portion define the entire width of the strap at any location along the length of the strap.

5. The main strap portion defines the entirety of one of the upper edge and lower edge portions of the strap, the rear portion of the breathing mask headgear according to any one of claims 1 to 4.

6. The main strap portion is the rear portion of the breathing mask headgear according to any one of claims 1 to 5, defining the entire width of the central part of the strap.

7. The rear portion of the breathing mask headgear according to any one of claims 1 to 6, wherein the at least one flange portion includes a first flange portion and a second flange portion located on both sides of the central portion of the strap.

8. The rear portion of the breathing mask headgear according to claim 7, wherein, during use, each of the first flange portion and the second flange portion extends substantially along the entire length of each side of the user's head.

9. The rear portion of a breathing mask headgear according to any one of claims 1 to 8, wherein the length of the upper strap is a first length, and the length of the lower strap is a second length, the second length being greater than the first length.

10. The rear portion of the breathing mask headgear according to any one of claims 1 to 9, wherein the width of the lower strap is greater than the width of the upper strap.

11. The rear portion of a breathing mask headgear according to any one of claims 1 to 10, wherein the living hinge is a first living hinge, and each joint further includes a second living hinge, the first living hinge being located between the base portion and the upper strap, and the second living hinge being located between the base portion and the lower strap.

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