Strap components

Abstract

Various methods for forming headbands for use with respiratory equipment are disclosed, the headband comprising an integral plastic core within a textile housing. In some configurations, the plastic core material penetrates or breaks through the textile housing of the strap. Some configurations include overlay molding, alignment posts, T-joints, and joint housings with injection holes. Various different headband arrangements are disclosed, including a top strap, a front strap, a rear strap, and paired straps extending above and below the ears from the mask to meet behind the ears. Various connectors for connecting the headband assembly to a mask assembly are disclosed, wherein when the connector is disengaged from the mask assembly, the headband, mask, and connector form a closed loop.

Description

[0001] This application is a divisional application of the invention patent application filed on March 9, 2017, with application number 201780030322.2 (international application number PCT / IB2017 / 051373) entitled "Strap assembly, strap connector, headband, headband assembly, method of forming headband, tubular connector, patient interface, and method of connecting strap".

[0002] By incorporating any priority claim

[0003] This application relates to and claims priority to the following applications: U.S. Provisional Patent Application No. 62 / 309,400, U.S. Provisional Patent Application No. 62 / 323,459, U.S. Provisional Patent Application No. 62 / 364,767, U.S. Provisional Patent Application No. 62 / 401,462, U.S. Provisional Patent Application No. 62 / 468,915, U.S. Provisional Patent Application No. 62 / 323,489 and U.S. Provisional Patent Application No. 62 / 327,942, the full contents of which are hereby incorporated herein by reference and constitute a part of this disclosure. Background Technology Technical Field

[0004] This disclosure generally relates to headbands used in conjunction with respiratory equipment. More specifically, this disclosure relates to three-dimensional headbands, the formation of multiple portions of the headband, and methods for molding such headbands. Further applications of this molding method are also disclosed. This disclosure also generally relates to full-face subnasal patient interfaces with closed-loop headbands, and various components of the patient interface.

[0005] Related technical specifications

[0006] The patient interface is used to deliver respiratory therapy to the airways of people suffering from any of a variety of respiratory diseases or conditions. Such therapies may include, but are not limited to, continuous positive airway pressure (CPAP) therapy and non-invasive ventilation (NIV) therapy.

[0007] CPAP therapy can be used to treat obstructive sleep apnea (OSA), a condition in which the airways of a patient intermittently collapse during sleep, thus preventing the patient from breathing for a period of time. The cessation of breathing, or pause in breathing, causes the patient to wake up. Repeated and frequent apneas can result in patients rarely sleeping through the night and therefore rarely recovering energy from nighttime sleep.

[0008] CPAP therapy involves delivering a continuous positive pressure supply to the patient's airway via a patient interface. CPAP acts as a splint within the patient's airway, holding it in an open position so that the patient's breathing and sleep are not interrupted.

[0009] Patient interfaces typically include a mask assembly and a headband assembly. The mask assembly is configured to deliver a continuous positive pressure supply to the patient's airway via a seal or pad that forms a substantially airtight seal in or around the patient's nose and / or mouth. A range of mask assemblies are available, including full-face masks, nasal masks, and direct oronasal masks, all of which form a substantially airtight seal with the nose and / or mouth. The seal or pad is held in place on the patient's face by the headband assembly. To maintain a substantially airtight seal, the headband assembly should provide support for the mask assembly so that it remains in a stable position relative to the patient's face during use. Such patient interfaces can also be used to deliver NIV and other therapies.

[0010] The patient interface forms at least a substantial "seal" over or around the user's nose and / or mouth, while the cannula does not provide a seal but does provide a delivery path for supplemental breathing gas. The result of this "seal" is that the closed area of ​​the breathing device, combined with its internal pressure, generates a resultant force attempting to push the breathing device away from the face. To counteract this force, a headband typically consists of a series of straps that wrap around the back and / or top of the user's head.

[0011] A common problem with adjustable headbands, or headbands that require left-right connection when using an under-nose mask, is that the user may pull one side of the headband too tight, causing the mask to pull off-center. In other cases, the user may simply pull the mask off-center by connecting only one side first. Under-nose masks may be more easily pulled off-center than over-the-nose masks because the nose may collapse, whereas over-the-nose masks are centered along with the apex of the mask seal. Therefore, it is desirable to develop a closed-loop headband design with a connection mechanism that connects to the mask assembly, ensuring that the patient interface seal remains centered on the user's face when putting on and taking off the headband. Summary of the Invention

[0012] The systems, methods, and apparatuses described herein have multiple innovative aspects, none of which are indispensable or can alone cause the desired properties of these aspects. Some of the advantageous features are now outlined without limiting the scope of the claims.

[0013] According to at least one embodiment disclosed herein, a headband is provided. The headband includes a top strap and a bottom strap, wherein the bottom strap is connected to the top strap at a location between end portions of the bottom strap. A monolithic plastic core is integrally formed within the textile housing of both the top and bottom straps.

[0014] According to another aspect, the integral plastic core material extends through at least one of the textile shells of both the top strap and the bottom strap.

[0015] On the other hand, these textile shells have a seamless tubular shape.

[0016] On the other hand, the outer shells of these textiles are knitted, woven, braided, or crocheted.

[0017] On the other hand, one end portion of the textile outer shell of the top strap comes into contact with the textile outer shell of the bottom strap.

[0018] According to another aspect, the textile outer shell of the top strap extends radially outward along the length of the top strap in a direction toward the end portion of the top strap.

[0019] According to another aspect, one end portion of the textile outer shell of the top strap has a sealing portion, which is formed by cutting with a hot cutter.

[0020] According to another aspect, the headband further includes a filament core bonded to the integral plastic core material within the bottom strap.

[0021] According to another aspect, the headband further includes strap connectors positioned on the outer surface of at least one of the top strap and the bottom strap, wherein these strap connectors are formed from a monolithic plastic core.

[0022] According to at least one embodiment of the embodiments disclosed herein, a method for forming a headband within a molding tool is provided. The method includes: placing a first tubular textile shell and a second tubular textile shell within a cavity of the molding tool; introducing molten plastic material into the molding tool and into the first tubular textile shell; pushing the molten plastic material through the first tubular textile shell into the second tubular textile shell; and then allowing the molten plastic material to solidify within the first and second textile shells to form a monolithic plastic core.

[0023] According to another aspect, pushing molten plastic material through a first tubular textile shell into a second tubular textile shell further includes displacing the threads of the first tubular textile shell to form gaps in the wall of the first tubular textile shell through which the molten plastic material flows into the second tubular textile shell.

[0024] According to another aspect, pushing molten plastic material through a first tubular textile shell into a second tubular textile shell further includes tearing the thread of the first tubular textile shell to form a hole in the wall of the first tubular textile shell through which the molten plastic material flows into the second tubular textile shell.

[0025] According to another aspect, placing the first tubular textile shell and the second tubular textile shell within the cavity of the molding tool further includes positioning the first tubular textile shell in contact with the second tubular textile shell.

[0026] According to another aspect, an open end portion of the first tubular textile shell abuts against the second tubular textile shell at a location between the end portions of the second tubular textile shell.

[0027] According to another aspect, the first tubular textile shell and the second tubular textile shell are in contact with each other at some locations between their end portions.

[0028] According to another aspect, the outer edge of the cavity narrows relative to the central portion of the cavity, such that the outer edges of the first tubular textile shell and the second tubular textile shell are locked to prevent molten plastic material from flowing between the outer edges of the first tubular textile shell and the second tubular textile shell.

[0029] According to another aspect, the central portion of the cavity includes protrusions that press down the surface of at least one of the first tubular textile shell and the second tubular textile shell, such that an indentation is integrally formed on the surface of at least one of the first tubular textile shell and the second tubular textile shell.

[0030] According to at least one embodiment disclosed herein, a method for forming a headband within a molding tool is provided. The method includes: placing a first tubular textile shell into a cavity of a first molding tool; positioning a portion of the first tubular textile shell in contact with an adjacent cavity having a connector portion; introducing molten plastic material into the first molding tool and into the first tubular textile shell; pushing the molten plastic material through the first tubular textile shell into the adjacent cavity; and then allowing the molten plastic material to solidify within the first tubular textile shell to form a first strap portion having an inner core and a connector portion formed of a single piece of plastic material.

[0031] According to another aspect, the method further includes: placing a first strap portion into a second molding tool; positioning one end portion of a second tubular textile shell above a connector portion such that it contacts the first tubular textile shell of the first strap portion; introducing molten plastic material into the second molding tool and into the second tubular textile shell; and then allowing the molten plastic material to solidify within the second tubular textile shell to form a second strap portion having an inner core formed of a single piece of plastic material, the inner core being connected to the connector portion of the first strap portion.

[0032] According to at least one embodiment disclosed herein, a headband assembly is provided. The headband assembly includes a top strap, an upper side strap connected to the top strap, and a lower side strap connected to the upper side strap. The upper and lower side straps are integrally formed as a single structure.

[0033] On the other hand, the upper and lower straps are formed into a closed loop structure.

[0034] On the other hand, the top strap, upper side strap, and lower side strap are integrated into a single structure based on the overall terrain.

[0035] On the other hand, the top strap, upper strap, and lower strap are formed into a closed loop structure.

[0036] On the other hand, the upper and lower straps are connected by an internally molded strip of fabric.

[0037] According to another aspect, the headband assembly further includes a neck panel attached to at least one of a top strap and a lower side strap.

[0038] According to another option, at least one of the top straps and the neck panel includes a breathable, moisture-wicking material.

[0039] On the other hand, the top straps consist of quilted textile material.

[0040] On the other hand, the integral plastic core material is formed within the upper and lower straps.

[0041] On the other hand, the integral plastic core material is formed within the top strap, upper strap, and lower strap.

[0042] According to at least one embodiment disclosed herein, a tubular connector is provided for abutting one end of a first strap against a sidewall of a second strap. The connector includes a first end having a shape corresponding to the shape of the end of the first strap, wherein the first end contacts or is positioned above the end of the first strap; a second end positioned opposite the first end and having a shape corresponding to the sidewall of the second strap, wherein the second end contacts or is positioned above the sidewall of the second strap; a cavity positioned between the first end and the second end; and a plastic core positioned within the cavity, wherein the plastic core integrally integrates the first strap and the second strap to form a single, integral structure.

[0043] According to another aspect, the first end overlaps with the end of the first strap.

[0044] According to another aspect, the end of the first strap is adjacent to the second strap.

[0045] According to another aspect, the second end overlaps with the sidewall of the second strap.

[0046] According to at least one embodiment of the embodiments disclosed herein, a method is provided for attaching one end of a first strap to a sidewall of a second strap within a molding tool. The method includes: positioning one end of a first tubular textile shell into a cavity of a tubular connector, and positioning a portion of a sidewall of a second tubular textile shell adjacent to or within the cavity of the tubular connector; placing the first and second tubular textile shells and the tubular connector into the cavity of the molding tool; introducing molten plastic material into the molding tool and into the first tubular textile shell; injecting the molten plastic material through the first tubular textile shell and the tubular connector into the second tubular textile shell; and then allowing the molten plastic material to solidify within the first and second tubular textile shells and the tubular connector to form an integral inner core within the first and second tubular textile shells and the tubular connector.

[0047] According to another aspect, positioning includes bringing the end of the first tubular textile shell against the second tubular textile shell.

[0048] According to at least one embodiment disclosed herein, a strap connector assembly for connecting a first strap and a second strap is disclosed, each of the straps including an integral plastic core located within a textile housing. The strap connector assembly includes: a first connector portion positioned at one end portion of the first strap; and a second connector portion positioned between the end portions of the second strap, the second connector portion including a protrusion of the integral plastic core extending through the textile housing of the second strap. The second connector portion is configured to align with the first connector portion to connect the first and second straps. According to another aspect, the thickness of the first connector portion is equal to the thickness of the second connector portion. According to another aspect, the first and second connector portions are configured to have a gap between them when aligned to connect the first and second straps. According to another aspect, the strap connector assembly further includes an alignment recess disposed on the first connector portion, the alignment recess being configured to engage a protrusion disposed on an inner surface of a molding tool to maintain the position of the first connector portion relative to the molding tool. According to another aspect, the strap connector assembly further includes an overmolded engagement portion overmolded over the first connector portion and the second connector portion. According to another aspect, the thickness of the overmolded engagement portion is equal to the thickness of the first connector portion and the thickness of the second connector portion. According to another aspect, the overmolded engagement portion contacts the textile housing of both the first strap and the second strap. According to another aspect, the shapes of the first connector portion and the second connector portion are defined to mate with each other. According to another aspect, the first connector portion includes an extension of an integral plastic core beyond the textile housing. According to another aspect, the first connector portion extends beyond one end of the textile housing. According to another aspect, the first connector portion and the second connector portion are respectively a male connector portion and a female connector portion. According to another aspect, each of the first connector portion and / or the second connector portion includes a tab. According to another aspect, the width of the first connector portion and / or the width of the second connector portion is equal to the width of the integral plastic core of the respective first strap and the second strap.

[0049] According to at least one embodiment disclosed herein, a strap connector assembly for connecting a first strap portion and a second strap portion is disclosed, each of which includes an integral plastic core located within a textile housing. The strap connector assembly includes a connecting tab forming part of the integral plastic core of one of the straps and configured for connecting the first and second strap portions; an alignment post projecting from the surface of the connecting tab; and an overmolded engagement portion overmolded over the connecting tab. According to another aspect, the thickness of the alignment post is greater than the thickness of the connecting tab. According to another aspect, the thickness of the alignment post is equal to the thickness of the overmolded engagement portion. According to another aspect, the overmolded engagement portion is formed of an elastomeric material. According to another aspect, the strap connector assembly further includes a label formed into the surface of the overmolded engagement portion.

[0050] According to at least one embodiment disclosed herein, a strap connector for connecting a first strap portion and a second strap portion, the strap portions including an integral plastic core located within a textile housing, the strap connector comprising: a housing having a plurality of outer cavities disposed at end portions of the housing and configured to receive the end portions of both the first and second strap portions; an inner cavity positioned between the outer cavities; and an injection port extending between the inner and outer cavities, wherein the integral plastic core of the strap portions extends through the injection port. According to another aspect, the height of the outer cavities is greater than the height of the inner cavities. According to another aspect, the height of the inner cavity is equal to the thickness of the integral plastic core within the textile housing.

[0051] According to at least one embodiment disclosed herein, a strap assembly for a headband is disclosed, the strap assembly comprising: a textile shell including an outer surface facing away from the user, an inner surface facing the user, and a cavity disposed between the outer surface and the inner surface; and a plastic core material positioned within the cavity of the textile shell, wherein the outer surface of the textile shell has a convex shape. According to another aspect, the inner surface of the textile shell has a substantially flat shape. According to yet another aspect, the inner surface of the textile shell has a concave shape.

[0052] According to at least one embodiment of the embodiments disclosed herein, a strap assembly for a headband is disclosed, the strap assembly comprising: a textile shell including an ear arch region configured for positioning above a user's ear; and a plastic core positioned within a cavity of the tubular textile shell, wherein the distance between the plastic core and the edge of the textile shell is greater in the ear arch region than in the remainder of the strap assembly.

[0053] According to at least one embodiment disclosed herein, a headband assembly is disclosed comprising: a headband loop configured to receive a top and rear portion of a user's head, the headband loop including: an integral plastic core integrally formed with a textile housing; and a connector tab portion formed of the integral plastic core and projecting through the textile housing between end portions of the headband loop; a front strap; and a connector positioned over the connector tab portion of the headband loop and an end portion of the front strap. According to another aspect, the connector is overmolded onto both the end portions of the headband loop and the front strap. According to another aspect, the thickness of the connector is equal to the thickness of the connector tab portion. According to another aspect, the thickness of the connector is equal to the thickness of the headband loop. According to another aspect, the headband loop further includes: an alignment tab extending from an end portion of the headband loop, the alignment tab forming part of the integral plastic core of the headband loop; and an alignment post protruding from the surface of the connecting tab.

[0054] According to at least one embodiment disclosed herein, a strap connector assembly for connecting a first strap portion and a second strap portion is disclosed, each of the strap portions including an integral plastic core located within a textile housing. The strap connector assembly includes: a first connector portion positioned at one end portion of the first strap; a second connector portion positioned between the end portions of the second strap and protruding through the textile housing of the second strap; and an overmolded engagement overlying the first and second connector portions. According to another aspect, at least one of the first and second connector portions further includes an alignment post protruding from a surface of the first strap, wherein the overmolded engagement surrounds the alignment post. According to another aspect, at least one of the first and second connector portions further includes a recessed region recessed within a surface of the first strap, wherein the recessed region receives overmolded material of the overmolded engagement. According to another aspect, the strap connector assembly further includes an alignment recess recessed into the surface of at least one of the first strap and the second strap, wherein the alignment recess is configured to engage a protrusion disposed on the inner surface of the molding tool to maintain the position of at least one of the first strap and the second strap relative to the molding tool.

[0055] According to at least one embodiment disclosed herein, a strap connector assembly is provided for connecting a first strap and a second strap within a molding tool. The straps are formed from an integral plastic core material injected into a tubular textile housing. The strap connector assembly includes: a male connector portion positioned at an end portion of the first strap; and a female connector portion positioned between end portions of the second strap and protruding through the tubular textile housing of the second strap. The female connector portion is configured to engage with the male connector portion such that the first and second straps are connected. The male and female connector portions are formed from molten integral plastic core material. According to another aspect, the thickness of the male connector portion is equal to the thickness of the female connector portion. According to another aspect, the strap connector assembly further includes a gap disposed between the male connector portion and the female connector portion. According to another aspect, the strap connector assembly further includes an alignment recess disposed on the male connector portion, the alignment recess being configured to engage a protrusion disposed on an inner surface of the molding tool to maintain the position of the male connector portion relative to the molding tool. According to another aspect, the strap connector assembly further includes an overmolded engagement portion overmolded over the male connector portion and the female connector portion. According to another aspect, the thickness of the overmolded engagement portion is equal to the thickness of the male connector portion and the thickness of the female connector portion. According to another aspect, the overmolded engagement portion contacts the tubular textile housing of both the first and second straps.

[0056] According to at least one embodiment disclosed herein, a strap connector assembly is provided for connecting a first strap portion and a second strap portion within a molding tool. These strap portions are formed from an integral plastic core material injected into a tubular textile housing. The strap connector assembly includes a connecting tab formed from the integral plastic core material and configured to connect the end portions of both the first and second strap portions; an alignment post projecting from the surface of the connecting tab; and an overmolded engagement portion overmolded over the connecting tab. According to another aspect, the thickness of the alignment post is greater than the thickness of the connecting tab.

[0057] According to another perspective, the thickness of the alignment post is equal to the thickness of the molded joint covering it.

[0058] On the other hand, the overmolded joint is formed of an elastomeric material.

[0059] According to another aspect, the strap connector assembly further includes a label formed into the surface of the overmolded joint.

[0060] According to at least one embodiment disclosed herein, a strap connector is provided for connecting a first strap portion and a second strap portion within a molding tool. These strap portions are formed from an integral plastic core material injected into a tubular textile housing. The strap connector includes: outer cavities disposed at end portions of the housing and configured to receive the end portions of both the first and second strap portions; an inner cavity positioned between the outer cavities; and an injection port in fluid communication with the inner and outer cavities and configured to receive the integral plastic core material.

[0061] On the other hand, the height of the outer cavity is greater than the height of the inner cavity.

[0062] On the other hand, the height of the inner cavity is equal to the thickness of the overall plastic core material inside the tubular textile shell.

[0063] According to at least one embodiment disclosed herein, a strap assembly for a headband is provided. The strap assembly includes: a tubular textile housing including an outer surface facing away from the user and an inner surface facing the user; and a plastic core material positioned within a cavity of the tubular textile housing. The outer surface of the tubular textile housing has a convex shape.

[0064] On the other hand, the inner surface of the textile tubular structure has a generally flat shape.

[0065] On the other hand, the inner surface of the tubular textile has a concave shape.

[0066] According to at least one embodiment disclosed herein, a headband assembly is provided. The headband assembly includes a headband loop strap configured to receive a top and rear portion of a user's head. The headband loop strap includes: a monolithic plastic core integrally formed within a textile housing of the headband loop strap; and a connector tab portion positioned to be formed of the monolithic plastic core and project through a tubular textile housing of the headband loop strap between end portions of the headband loop strap. The headband assembly further includes a front strap and a connector positioned above the connector tab portion of the headband loop strap and one end portion of the front strap.

[0067] On the other hand, the connector is overmolded onto the end portions of both the headband loop and the front strap.

[0068] On the other hand, the thickness of the connector is equal to the thickness of the connector tab portion.

[0069] On the other hand, the thickness of the connector is equal to the thickness of the headband loop strap.

[0070] According to another aspect, the headband loop further includes: an alignment tab extending from the end portion of the headband loop, the alignment tab being formed of an integral plastic core; an alignment post protruding from the surface of the connecting tab; and an overmolded joint overmolded above the alignment tab and configured to connect the end portion of the headband loop.

[0071] According to at least one embodiment disclosed herein, a strap connector assembly is provided for connecting a first strap portion and a second strap portion within a molding tool. These strap portions are formed from an integral plastic core material injected into a tubular textile housing. The strap connector assembly includes: a first connector portion positioned at one end portion of the first strap; a second connector portion positioned between the end portions of the second strap and protruding through the tubular textile housing of the second strap; and an overmolded engagement overlying the first and second connector portions.

[0072] According to another aspect, at least one of the first connector portion and the second connector portion further includes an alignment post protruding from the surface of the first strap, wherein the alignment post is surrounded by an overmolded engagement portion.

[0073] According to another aspect, at least one of the first connector portion and the second connector portion further includes a recessed area recessed within the surface of the first strap, wherein the recessed area receives the overmolding material of the overmolded joint.

[0074] According to another aspect, the strap connector assembly further includes an alignment recess recessed into the surface of at least one of the first strap and the second strap, wherein the alignment recess is configured to engage a protrusion disposed on the inner surface of the molding tool to maintain the position of at least one of the first strap and the second strap relative to the molding tool.

[0075] In some configurations, the headband assembly for the patient interface includes a headband and at least one connector. The headband includes a top strap, a front strap, and a rear strap. The connector includes a first strap and a second strap. The first strap is configured to extend from the face mask assembly above and behind the user's ears. The second strap is configured to extend from the face mask assembly below and behind the user's ears. The first strap meets the second strap at a rear connector portion. The connector includes at least one headband connection surface configured for connection to the headband. The headband includes at least one connector connection surface configured for connection to at least one headband connection surface of the connector.

[0076] In some configurations, one or more of the top strap, rear strap, and front strap of the headband include separate left and right sections, each with a free end. The free ends of the left and right sections are adjustablely connected to each other.

[0077] In some configurations, the top strap and the front strap converge at the connection point.

[0078] In some configurations, this connection forms part of the periauricular ring.

[0079] In some configurations, the back strap forms part of the periauricular ring.

[0080] In some configurations, the periauricular ring is set to surround the user's ear but not to make contact with it.

[0081] In some configurations, at least one connector connection surface is configured to connect to at least one headband connection surface along a C-shaped connection area extending from above the user's ear to below the ear.

[0082] In some configurations, at least one connector connection surface is configured to connect along a connection line to at least one headband connection surface, the connection line extending from behind the user's ear to above the ear, wherein the entire connection line is configured to be positioned above the lowest part of the user's ear.

[0083] In some configurations, the patient interface includes the mask assembly and headband assembly as described above.

[0084] In some configurations, the headband assembly for the patient interface includes a headband and at least one connector. The headband includes a top strap, a front strap, and a rear strap. The connector includes a middle strap and a lower strap. The middle strap is configured to extend from the face mask assembly above and behind the user's ears. The lower strap is configured to extend from the face mask assembly below and behind the user's ears. The middle strap meets the lower strap at a rear connector portion. The connector includes at least one headband connection surface configured for connection to the headband. The headband includes at least one connector connection surface configured for connection to the connector.

[0085] A patient interface is provided according to at least one embodiment of the embodiments disclosed herein. The patient interface includes a headband assembly, a face mask assembly, and a connector portion for connecting the headband assembly to the face mask assembly. When the connector is disengaged from the face mask assembly, the headband assembly, the face mask assembly, and the connector portion form a closed loop.

[0086] According to another aspect, the effective length of the closed loop increases when the connector portion is disengaged from the mask assembly compared to the effective length of the closed loop when the connector portion is engaged with the mask assembly.

[0087] On the other hand, the connector portion is attached to the mask assembly via a hinge portion.

[0088] On the other hand, the connector part is attached to the mask assembly via a tether.

[0089] On the other hand, the hinge part is a movable hinge.

[0090] On the other hand, the hinge portion is made of silicone resin.

[0091] On the other hand, the movable hinge is made of fabric.

[0092] According to another embodiment, the patient interface further includes a hook disposed on the mask assembly and a post disposed on the connector portion. The post receives the hook for engagement with the mask assembly.

[0093] On the other hand, the connector part engages with the mask assembly via a snap-fit ​​or interference fit.

[0094] On the other hand, the headband assembly has straps formed from textile shells in which an integral plastic core is integrally formed.

[0095] According to another aspect, the difference between the effective length of the closed loop when the connector part is disengaged from the mask assembly and the effective length of the closed loop when the connector part is engaged with the mask assembly is at least 40 mm.

[0096] Further aspects of one or more embodiments of the invention should be considered in all their novel aspects, which will become apparent from the following description. Attached Figure Description

[0097] Throughout the accompanying drawings, reference numerals may be repeatedly used to indicate the general correspondence between reference elements. The drawings are provided to illustrate exemplary embodiments described herein and are not intended to limit the scope of this disclosure.

[0098] Figure 1A A side view of the bifurcation headband arrangement formed by the burst-through intra-moulding arrangement disclosed herein is shown.

[0099] Figure 1B A top perspective view of the bifurcation headband arrangement disclosed herein is shown.

[0100] Figure 2AA close-up side view of the connection between the top strap and the bottom strap of the bifurcated headband arrangement disclosed herein is shown.

[0101] Figure 2B A close-up side view of the connection between the top strap and the bottom strap of the bifurcated headband arrangement disclosed herein is shown.

[0102] Figure 3 A cross-sectional view is shown of the connection between the top strap and the bottom strap of the bifurcated head strap arrangement disclosed herein.

[0103] Figure 4 A perspective view of the injection molding tool used to form the bifurcated headband arrangement disclosed herein is shown.

[0104] Figure 5 This is a top-down view showing the second tool half of the injection molding tool.

[0105] Figure 6 A close-up top perspective view shows the top and bottom straps positioned within the second tool half of the injection molding tool.

[0106] Figure 7 A bottom cross-sectional view of the fully formed bifurcated headband section is shown.

[0107] Figure 8A A perspective view of the second tool half is shown, illustrating an alternative internally molded strap cavity arrangement for forming the X-shaped and T-shaped connectors.

[0108] Figure 8B A top-down view shows the arrangement of straps with X-shaped and T-shaped connectors.

[0109] Figure 9A A top-down view shows an alternative internally molded strap arrangement with multiple straps connected together by integrally formed connecting members positioned between the straps.

[0110] Figure 9B A top-down view shows an alternative internally molded strap arrangement with multiple straps linked together by an integrally formed fiber web portion positioned between the straps.

[0111] Figure 10A A top-down view shows an alternative internally molded strap arrangement with chamfered connections that attach chamfered straps to adjacent straps.

[0112] Figure 10B A top perspective view shows the injection molding tool used to form the chamfered joint.

[0113] Figure 11AA top-down view shows the internal molded strap arrangement, which has molded square textures embossed into the straps.

[0114] Figure 11B This shows a close-up, top-down view of the molded square texture embossed into the straps.

[0115] Figure 11C The molded square texture embossed into the straps is shown along Figure 11B A cross-sectional view of line 11C-11C in the diagram.

[0116] Figure 11D A top-down view shows the internal molded strap arrangement, which has a molded hexagonal texture embossed into the straps.

[0117] Figure 11E A side perspective view showing the molded hexagonal texture embossed into the straps.

[0118] Figure 12A A top-down view shows a first molding tool for forming the bottom strap of an internally molded forked headband, the bottom strap having an attachment member.

[0119] Figure 12B A close-up top-down view of the first molding tool is shown, revealing the bottom straps and attachment components.

[0120] Figure 13A A top-down view shows a second molding tool used to form a top binding strap above the attachment member.

[0121] Figure 13B A close-up top-down view of the second molding tool is shown, illustrating the top strap attached to the bottom strap.

[0122] Figure 13C A close-up cross-sectional view of the top strap positioned above the attachment member before the plastic core material is injected into the top strap is shown.

[0123] Figure 13D A close-up cross-sectional view is shown of the top strap attached to the attachment member after the plastic core material is injected into the top strap.

[0124] Figure 14A A close-up side view of the top strap is shown, which has a sealed end at the connection with the bottom strap.

[0125] Figure 14B A close-up side view of the top strap with a sealed end is shown.

[0126] Figure 14CA close-up side view of the top strap is shown, which has a sealed end that attaches to the bottom strap at the connection point.

[0127] Figure 14D A cross-sectional view of the connection between the top and bottom straps is shown.

[0128] Figure 15A A close-up cross-sectional side view of a top strap attached to a bottom strap, the top strap having a filament core that engages with a transition locking arrangement, is shown.

[0129] Figure 15B The image shows a top-down view of the forked headband section, which has a bottom strap incorporating a fine filament core.

[0130] Figure 15C A top-down view is shown, illustrating the stretched length of the shell with the bottom straps.

[0131] Figure 15D A top-down view is shown, illustrating how the shell of the bottom strap narrows when stretched.

[0132] Figure 16A A side perspective view is shown of an alternative forked headband arrangement with a button and hole size adjustment system, which is formed by the breakthrough internal molding device disclosed herein.

[0133] Figure 16B A cross-sectional view of the top and bottom straps with button and hole size adjustment systems is shown.

[0134] Figure 16C This is a side perspective view of the injection molding tool used to form the button and the hole size adjustment system.

[0135] Figure 16D The image shows cross-sectional views of the first and second halves of the molding tool during the process of making a button and hole size adjustment system.

[0136] Figure 17 An adjustable strap arrangement with adjustable and usability features formed by a breakthrough in-mold process is demonstrated.

[0137] Figure 18 An internally molded headband with multiple straps and several breakthrough connections was showcased.

[0138] Figure 19 An exemplary headband is shown that combines an internal molding process with a breakthrough process, as well as an additional comfort layer.

[0139] Figure 20Another exemplary headband is shown, which combines an internal molding process with a breakthrough process, as well as an additional comfort layer.

[0140] Figure 21 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a fiber mesh portion that connects the rear portions of the lower and middle straps.

[0141] Figure 22 Another exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a continuous lower strap.

[0142] Figure 23 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a fiber mesh portion that connects the rear portions of the lower and middle straps.

[0143] Figure 24 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and features a continuous lower strap and a combined continuous middle vertical strap.

[0144] Figure 25 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0145] Figure 26 Another exemplary headband is shown, which combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0146] Figure 27 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has multiple parts that are attached to the headband and come into direct contact with the user's skin or hair.

[0147] Figure 28 Another exemplary headband is shown, which combines an internal molding process and a breakthrough process and has multiple parts that are attached to the headband and come into direct contact with the user's skin or hair.

[0148] Figure 29 An exemplary headband is shown, which combines an in-house molding process with a breakthrough process and features vertical straps and a neck strap formed from foam-Lycra laminate.

[0149] Figure 30 An exemplary headband is shown that combines an in-house molding process with a breakthrough process and features breathable, moisture-wicking material in the vertical straps and neck strap.

[0150] Figure 31 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0151] Figure 32 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a bottom lower strap, a middle strap and a front vertical strap in the form of a closed loop structure formed by a continuous shell.

[0152] Figure 33 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0153] Figure 34 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0154] Figure 35 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap with a continuous shell.

[0155] Figure 36 An exemplary headband is shown that combines an internal molding process and a breakthrough process, and has a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0156] Figure 37 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a lower strap and a middle strap formed by a continuous shell.

[0157] Figure 38 Another exemplary headband is shown, which combines an internal molding process and a breakthrough process, and features a lower strap and a middle strap formed from a continuous shell.

[0158] Figure 39 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a lower strap and a middle strap formed by a continuous shell.

[0159] Figure 40 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a lower strap, a middle strap and a vertical strap formed by a continuous shell.

[0160] Figure 41An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a lower strap, a middle strap and a vertical strap formed by a continuous shell.

[0161] Figure 42 An exemplary headband is shown, which combines an internal molding process and a breakthrough process and has a lower strap and a middle strap formed by a continuous shell.

[0162] Figure 43A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0163] Figure 43B yes Figure 43A The rear perspective view of the exemplary headband in the image.

[0164] Figure 44A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0165] Figure 44B yes Figure 44A The rear perspective view of the exemplary headband in the image.

[0166] Figure 45A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0167] Figure 45B yes Figure 45A The rear perspective view of the exemplary headband in the image.

[0168] Figure 46A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0169] Figure 46B yes Figure 46A A side view of an exemplary headband.

[0170] Figure 46C yes Figure 46A The rear perspective view of the exemplary headband in the image.

[0171] Figure 47A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0172] Figure 47B yes Figure 47A The rear perspective view of the exemplary headband in the image.

[0173] Figure 48A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0174] Figure 48B yes Figure 48A The rear perspective view of the exemplary headband in the image.

[0175] Figure 49A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0176] Figure 49B yes Figure 49A The rear perspective view of the exemplary headband in the image.

[0177] Figure 50A This is a front perspective view of an exemplary headband that can be used with a patient interface.

[0178] Figure 50B yes Figure 50A The rear perspective view of the exemplary headband in the image.

[0179] Figure 51A This is a side view of an exemplary headband that can be used with a patient interface.

[0180] Figure 51B yes Figure 51A A cross-sectional view of the strap portion of an exemplary headband.

[0181] Figure 52A This is a side view of an exemplary headband that can be used with a patient interface.

[0182] Figure 52B yes Figure 52A A cross-sectional view of the strap portion of an exemplary headband.

[0183] Figure 52C yes Figure 52A A cross-sectional view of the strap portion of an exemplary headband.

[0184] Figure 53A This is a side view of an exemplary headband that can be used with a patient interface.

[0185] Figure 53B yes Figure 53A A cross-sectional view of the strap portion of an exemplary headband.

[0186] Figure 54A This is a side view of an exemplary headband that can be used with a patient interface and has a lower strap and a middle strap formed by a continuous shell.

[0187] Figure 54B yes Figure 54A A close-up view of the fiber mesh portion of an exemplary headband.

[0188] Figure 54C It is the fiber web section along Figure 54B The cross-sectional view of line 54C-54C in the diagram.

[0189] Figure 55A This is a side view of an exemplary headband that can be used with a patient interface and has a continuous lower strap and a combined continuous middle vertical strap.

[0190] Figure 55B The fiber mesh portion of the exemplary headband is along Figure 55A The cross-sectional view of line 55B-55B in the diagram.

[0191] Figure 55C yes Figure 55A A close-up view of the fiber mesh portion of an exemplary headband.

[0192] Figure 56A This is a side view of an exemplary headband that can be used with a patient interface, the headband having a lower strap and a middle strap in the form of a closed loop structure formed by a continuous shell.

[0193] Figure 56B yes Figure 56A A close-up view of the connector of an exemplary headband.

[0194] Figure 57A This is a side view of an exemplary headband that can be used with a patient interface and has a lower strap and a middle strap formed by a continuous shell.

[0195] Figure 57B yes Figure 57A A close-up view of the second vertical member of the exemplary headband.

[0196] Figure 57C It is the second vertical member along Figure 57B Cross-sectional view of line 57C-57C in the diagram.

[0197] Figure 58A This is a side view of an exemplary headband that can be used with a patient interface.

[0198] Figure 58B yes Figure 58A A close-up view of the connector of an exemplary headband.

[0199] Figure 59A This is a side view of an exemplary headband that can be used with a patient interface and has a continuous central vertical strap and a continuous upper rear strap.

[0200] Figure 59B yes Figure 59A A close-up view of the exemplary headband's continuous central vertical strap and continuous upper rear strap.

[0201] Figure 59C It consists of continuous vertical straps in the middle and continuous upper and rear straps along the... Figure 59Aand Figure 59B Cross-sectional view of line 59C-59C in the diagram.

[0202] Figure 60A This is a side view of an exemplary headband that can be used with a patient interface.

[0203] Figure 60B yes Figure 60A A close-up view of the rear strap of an exemplary headband.

[0204] Figure 61A This is a side view of an exemplary headband that can be used with a patient interface and has a continuous central vertical strap and a continuous upper rear strap.

[0205] Figure 61B yes Figure 61A A close-up view of the rear section of the middle and lower straps of the exemplary headband.

[0206] Figure 61C It consists of continuous vertical straps in the middle and continuous upper and rear straps along the... Figure 61B Cross-sectional view of line 61C-61C in the diagram.

[0207] Figure 62A This is a side view of an exemplary headband that can be used with a patient interface.

[0208] Figure 62B yes Figure 62A A close-up view of a variant of an exemplary headband.

[0209] Figure 63A It is a side view of an exemplary headband that can be used with a patient interface and has multiple portions provided to be attached to the headband and in direct contact with the user's skin or hair.

[0210] Figure 63B yes Figure 63A A close-up view of the quilted fabric of an example headband.

[0211] Figure 63C yes Figure 63A A close-up view of the alternative fiber mesh portion of the exemplary headband shown.

[0212] Figure 64A It is a side view of an exemplary headband that can be used with a patient interface and has multiple portions provided to be attached to the headband and in direct contact with the user's skin or hair.

[0213] Figure 64B yes Figure 64A A close-up view of the fabric or textile material of an exemplary headband.

[0214] Figure 65 This is a close-up view of a trademarked gripper that can be used with one embodiment of the disclosed headband.

[0215] Figure 66A This is a side view of the T-shaped connection between one end of the first strap and the central portion (or middle portion) of the second strap.

[0216] Figure 66B It is used to form Figure 66A A close-up view of the connector with the T-shaped connection in the middle.

[0217] Figure 67 This is a perspective view of the T-shaped connector.

[0218] Figure 68A This is a bottom view of the connector.

[0219] Figure 68B This is a side view of the connector.

[0220] Figure 68C This is a top view of the connector.

[0221] Figure 68D This is a perspective view of the connector.

[0222] Figure 69 This is a side view of the T-shaped connector, showing the connector positioned above the first strap, such that the end of the first strap is positioned inside the connector.

[0223] Figure 70 This is a perspective view of the connector and the T-shaped connection.

[0224] Figure 71 This is a close-up side view of the filled connector and T-shaped connection.

[0225] Figure 72 It is a cross-sectional view of the filled connector and T-shaped connection.

[0226] Figure 73 This is a side view of the filled connector and T-shaped connection.

[0227] Figure 74A A top view of an exemplary headband arrangement is shown, the top strap having a male connector for forming an overlay molded joint.

[0228] Figure 74B A top view of the bottom strap of this exemplary headband arrangement is shown, which has a female connector for forming an overlay molded joint.

[0229] Figure 75AA close-up top view of the male connector with the top strap is shown.

[0230] Figure 75B A close-up cross-sectional view of the male connector with the top strap is shown.

[0231] Figure 76A A close-up top view of the female connector with the bottom strap is shown.

[0232] Figure 76B A close-up cross-sectional view of the female connector with the bottom strap is shown.

[0233] Figure 76C A close-up perspective view of the female connector with the bottom strap is shown.

[0234] Figure 77A A close-up top view of the aligned male and female connectors is shown.

[0235] Figure 77B A close-up top view shows the male connector inserted into and accepted by the female connector.

[0236] Figure 77C This shows a close-up cross-sectional view of the male connector inserted into and received by the female connector.

[0237] Figure 78A A close-up side view of the male and female connectors is shown, revealing the small gap between them.

[0238] Figure 78B A close-up side view of the male and female connectors is shown, revealing a large gap between them.

[0239] Figure 79A A close-up top view of the male connector is shown.

[0240] Figure 79B A perspective view of the overmolding cavity of the overmolding tool is shown.

[0241] Figure 79C A cross-sectional view of the male connector in the overmolding cavity of the overmolding tool is shown.

[0242] Figure 80A A close-up top view of the molded overlay joint that combines top and bottom straps is shown.

[0243] Figure 80B A perspective view of the overmolded joint that combines top and bottom straps is shown.

[0244] Figure 80CA cross-sectional bottom view of the overmolded joint that incorporates top and bottom straps is shown.

[0245] Figure 81A The image shows a close-up top view of the connecting tabs and alignment posts before the two halves are overmolded to connect the bottom straps.

[0246] Figure 81B Showing Figure 81A A close-up bottom view of the connecting pieces and alignment posts.

[0247] Figure 81C Showing Figure 81A A close-up cross-sectional view of the connecting pieces and alignment posts.

[0248] Figure 81D Showing Figure 81A A close-up top view of the connecting tabs and the overmolded part formed above the alignment post.

[0249] Figure 81E Showing Figure 81D A close-up bottom view of the overmolded part.

[0250] Figure 82A A side view of the housing at the end of the strap is shown.

[0251] Figure 82B Showing Figure 82A A perspective view of the housing at the end of the strap.

[0252] Figure 83A Showing Figure 82A A top view of the housing at the end of the strap.

[0253] Figure 83B Showing Figure 82A Side view of the housing at the end of the strap.

[0254] Figure 83C Showing Figure 82A End view of the housing at the end of the strap joint.

[0255] Figure 83D Showing the tie end joint housing along Figure 83A Side cross-sectional view of line 83D-83D in the middle.

[0256] Figure 83E Showing the tie end joint housing along Figure 83B Cross-sectional view of the end of line 83E-83E in the middle.

[0257] Figure 84A A side cross-sectional view of a strap with a D-shaped cross-section is shown, the strap having a flange portion formed along its edge.

[0258] Figure 84B A side cross-sectional view of a strap with a D-shaped cross-section is shown, which does not have a flange portion formed along its edge.

[0259] Figure 85 A top view of the strap is shown, which has a bottom strap with a soft edge positioned above the user's ear.

[0260] Figure 86 A side view shows a forked headband arrangement with a rear headband loop strap, formed by a breakthrough internal molding device.

[0261] Figure 87A Showing Figure 86 A top view of the rear headband loop strap.

[0262] Figure 87B Showing Figure 86 A close-up top view of the breakout patch of the rear headband loop strap.

[0263] Figure 87C Showing Figure 86 A close-up top view of the alignment patch of the rear headband loop strap.

[0264] Figure 88A Showing Figure 86 A top view of the alignment patch of the rear headband loop strap.

[0265] Figure 88B The alignment tabs of the rear headband loop straps are shown. Figure 87C Close-up cross-sectional view of lines 88B-88B in the diagram.

[0266] Figure 89A A top view shows the covered molded joint where the rear headband loop strap is attached to the front strap.

[0267] Figure 89B Showing Figure 89A Close-up cross-sectional view of the overmolded joint along line 89B-89B.

[0268] Figure 90A A perspective view showing the top strap with alignment posts and indentations is presented.

[0269] Figure 90B Showing Figure 90A Bottom view of the top strap in the image.

[0270] Figure 90C A top view showing the bottom strap with alignment posts and a dent.

[0271] Figure 90D Showing Figure 90C A top view of the bottom strap in the image, which has an alignment post, post hole, and indentation.

[0272] Figure 91A Showing Figure 90A The top strap in the middle and Figure 90C A perspective view showing the bottom strap aligned with the center.

[0273] Figure 91B Showing Figure 90A The top strap in the middle and Figure 90C The bottom view is aligned with the bottom strap.

[0274] Figure 91C Showing Figure 90A The top strap in the middle and Figure 90C A perspective view showing the bottom strap aligned with the center.

[0275] Figure 91D Showing Figure 90A The top strap in the middle and Figure 90C A perspective cross-sectional view with the bottom strap aligned.

[0276] Figure 92A Demonstrating Figure 90A The top strap in the middle and Figure 90C Bottom view of the molded joint where the bottom straps are joined together.

[0277] Figure 92B Showing Figure 92A A top view of the molded joint.

[0278] Figure 92C Showing Figure 92A A perspective cross-sectional view of the molded joint in the middle.

[0279] Figure 92D A perspective cross-sectional view of the overmolded connector is shown.

[0280] Figure 93A This is a perspective view of a non-limiting exemplary embodiment of a patient interface having a headband assembly and a face mask assembly according to this disclosure. The headband assembly includes a headpiece and one or more connectors located between the headpiece and the face mask assembly.

[0281] Figure 93B yes Figure 93A A perspective view of the patient interface, where the connector is disconnected from the headgear.

[0282] Figure 93C yes Figure 93A The back perspective view of the patient interface.

[0283] Figure 94AThis is a perspective view of another non-limiting exemplary embodiment of a patient interface having a headband assembly and a face mask assembly according to this disclosure. The headband assembly includes a headpiece and one or more connectors located between the headpiece and the face mask assembly.

[0284] Figure 94B yes Figure 94A A perspective view of the patient interface, where the connector is disconnected from the headgear.

[0285] Figure 94C yes Figure 94A The back perspective view of the patient interface.

[0286] Figure 95 An isometric view of the patient interface disclosed herein is shown, which includes a headband, a face mask assembly, and a connector.

[0287] Figure 96 It shows Figure 95 The rear isometric view of the patient interface.

[0288] Figure 97 An isometric view of the patient interface is shown, illustrating the connector disengaging from the mask assembly.

[0289] Figure 98 It shows Figure 97 An isometric view of the patient interface, showing the connector fully extended away from the mask assembly.

[0290] Figure 99A An isometric view of the movable hinge connector is shown.

[0291] Figure 99B An isometric view of an alternative active hinge connector is shown.

[0292] Figure 100 A top view of an active hinge connector with multiple segments having reduced thickness is shown.

[0293] Figure 101A An isometric exploded view of the active hinge connector is shown.

[0294] Figure 101B It shows Figure 101A Cross-sectional view of the headband connector component and the face shield connector component of the active hinge connector.

[0295] Figure 102A An isometric view of an active hinge connector with a single mask hinge and a single connector hinge is shown.

[0296] Figure 102B It shows Figure 102A Top cross-sectional view of the headband connector component and face shield connector component of the active hinge connector.

[0297] Figure 103A An isometric view of a patient interface with a movable hinge connector having a hook and post retention system is shown.

[0298] Figure 103B It is shown in the open position. Figure 103A The front view of the movable hinge connector shown.

[0299] Figure 104A An isometric view of a patient interface with a fabric movable hinge connector in the closed position is shown.

[0300] Figure 104B It shows Figure 104A An isometric view of the patient interface, showing the fabric active hinge connector in the open position.

[0301] Figure 105A An isometric view of a patient interface with a silicon hinge connector in the closed position is shown.

[0302] Figure 105B It shows Figure 105A An isometric view of the patient interface, showing the silicon hinge connector in the open position.

[0303] Figure 106A A top-down view of an alternative silicon hinge is shown, with the connector in the closed position.

[0304] Figure 106B It shows Figure 106A A top-down view of a silicon hinge with the connector in the open position.

[0305] Figure 107A An isometric view of a patient interface with an alternative silicon hinge connector in the closed position is shown.

[0306] Figure 107B It is shown in the open position. Figure 107A An isometric view of the silicon hinge connector shown.

[0307] Figure 108A An isometric view of the patient interface is shown, in which the headband connection of this disclosure is illustrated.

[0308] Figure 108B It shows Figure 108A A close-up perspective view of the side end of the connector for the headband connection.

[0309] Figure 108C It shows Figure 108A A cross-sectional view of the connector for the headband connection.

[0310] Figure 109A An isometric view of the headband fixing mechanism is shown.

[0311] Figure 109B A top view of the alternative headband securing mechanism is shown.

[0312] Figure 110A An isometric view of the push-in headband fixing mechanism is shown.

[0313] Figure 110B A cross-sectional view of the push-in headband fixing mechanism is shown.

[0314] Figure 111A An isometric view of a patient interface with a connector featuring a top-centered clamp design in the closed position is shown.

[0315] Figure 111B It shows Figure 111A An isometric view of the patient interface, showing the upper centered clamp design connector in the open position.

[0316] Figure 112A An isometric view of a patient interface with an extendable pivot connector in the closed position is shown.

[0317] Figure 112B It shows Figure 112A An isometric view of the patient interface, showing the extendable pivot connector in the open position.

[0318] Figure 112C It shows Figure 112A An isometric view of the patient interface, showing the extendable pivot connector in both open and extended positions.

[0319] Figure 113A An isometric view of a patient interface with a hard-stop sliding strap connector is shown, in the closed position.

[0320] Figure 113B It shows Figure 113A An isometric view of the patient interface, showing the hard-stop sliding strap connector in the open position.

[0321] Figure 114A An isometric view of a patient interface with a strap-end hard-stop connector is shown in the closed position.

[0322] Figure 114B It shows Figure 114A An isometric view of the patient interface, showing the hard-stop connector at the end of the strap in the open position.

[0323] Figure 115A An isometric view of a patient interface with a disconnectable magnet and a tether connector in the closed position is shown.

[0324] Figure 115B It shows Figure 115A An isometric view of the patient interface, showing the disconnected mating magnet and tether connector in the open position.

[0325] Figure 116A An isometric view of a patient interface with a disconnecting clamp and a tether connector in the closed position is shown.

[0326] Figure 116B It shows Figure 116A An isometric view of the patient interface, showing the disconnected mating clamp and tether connector in the open position.

[0327] Figure 117A An isometric view of a patient interface with a clamp and a continuous tether connector in the closed position is shown.

[0328] Figure 117B It shows Figure 117A An isometric view of the patient interface, showing the clamp and continuous tether connector in the open position.

[0329] Figure 118A A front view of a patient interface with dual clamps and continuous tether connectors in the closed position is shown.

[0330] Figure 118B It shows Figure 118A An isometric view of the patient interface, showing the dual clamps and continuous tether connector in the closed position.

[0331] Figure 119A An isometric view of a patient interface with a clamp and a rigid tether connector in the closed position is shown.

[0332] Figure 119B It shows Figure 119A An isometric view of the patient interface, showing the clamp and rigid tether connector in the open position.

[0333] Figure 120A An isometric view of a patient interface with a hook and pin ring connector in the closed position is shown.

[0334] Figure 120B It shows Figure 120A An isometric view of the patient interface, showing the hook and pin ring connector in the open position.

[0335] Figure 121A An isometric view of a patient interface with an alternative hook and pin-ring connector is shown in the closed position.

[0336] Figure 121B It shows Figure 121A An isometric view of the patient interface, showing an alternative hook and pin ring connector in the open position. Detailed Implementation

[0337] Embodiments of systems, components, and methods of assembly and manufacture will now be described with reference to the accompanying drawings, wherein similar numerals refer to similar or analogous elements throughout. Although several embodiments, examples, and illustrations are disclosed below, it will be understood by those skilled in the art that the invention described herein extends beyond the specifically disclosed embodiments, examples, and illustrations, and may include other uses of the invention and its obvious modifications and equivalents. The terminology used in the description presented herein is not intended to be interpreted simply in any limiting or restrictive manner, as the terminology is used in conjunction with the detailed description of certain specific embodiments of the invention. Furthermore, embodiments of the invention may include several novel features, and no single feature alone causes its desired properties, nor is any single feature essential for practicing the invention described herein.

[0338] Certain terms used in the following description may be for illustrative purposes only and are not intended to be limiting. For example, terms such as “above” and “below” refer to directions of reference in the accompanying drawings. Terms such as “front,” “back,” “left,” “right,” “rear,” and “side” describe the orientation and / or position of portions of a component or element within a consistent but arbitrary frame of reference, which is made clear by reference to the text describing the components or elements discussed and the associated drawings. Furthermore, terms such as “first,” “second,” and “third” may be used to describe individual components. Such terms may include the words specifically mentioned above, their derivatives, and words with similar meanings.

[0339] As used herein, the term "substantially inelastic" refers to the ability of a headband or material to resist tension relative to the load it can withstand. Therefore, a headband or material may be substantially inelastic in one direction and somewhat elastic in another. In some configurations, a headband or material is configured to be substantially inelastic in the direction of the load applied in the therapy intended to use the headband or material. A substantially inelastic headband or material can, for example, resist tension that could compromise the seal of a breathing mask in a sealed system under normal or intended conditions. In a non-sealed system, a substantially inelastic headband or material can, for example, resist tension that could compromise the proper arrangement of the breathing interface in response to normal or intended conditions, such as hose tension or user movement. When the anticipated load is relatively small, the headband or material can have greater elasticity because the load will not be sufficient to cause tension. Conversely, if the headband and / or material is expected to withstand high loads, then greater inelasticity will be required to resist tension.

[0340] Throughout this specification, references are made to “breakthrough” molding, methods, techniques, and parts manufactured by such molding, methods, and techniques. References also include “breakthrough in-mold molding” and “in-mold breakthrough.” It should be understood that all these references are general references to embodiments of this disclosure and are not intended to be explicit limitation.

[0341] headband

[0342] Figure 1A A non-limiting exemplary embodiment of the internally molded bifurcated headband 100 disclosed herein, used in conjunction with a breathing device 110, is shown. "Internally molded" includes forming a component as a plastic core and a textile shell as an integral structure by applying molten plastic into a textile shell. Straps or any other components that have been "internal molded" are components formed by applying molten plastic into a textile shell.

[0343] Figure 1A and Figure 1B The bifurcated headband 100 is shown configured to be substantially inelastic and structurally three-dimensional (3D). The bifurcated headband design is superior to a single-strap design because it provides improved stability on the patient's head as the headband is supported at multiple points on the user's head. As used herein, a three-dimensional structure is not situated in a single plane but is shaped to extend across multiple planes. In other words, the three-dimensional structure is not flat. The headband 100 shown includes a right side 120 and a left side 130. Both the right side 120 and the left side 130 include a top strap 140, a bottom strap 150, and a face mask connector 180.

[0344] The top strap 140 has an elongated shape and includes a lateral end portion 142 and a central end portion 144. The top strap 140 is configured to be generally located above each of the user's ears and extends upward from the lateral end portion 142 at a location on the parietal or frontal region of the user's head, then terminates at the central end portion 144. The central end portion 144 is configured to be positioned at or near a central point or central location on the top of the user's head. The central end portions 144 of the top straps on the right side 120 and left side 130 are configured to be joined together at a location on the top of the user's head via a top joint 190. The top joint 190 may include stitching, welding, bonding, overmolding, or any other fastening arrangement, which may be permanent or removable / detachable. In some arrangements, the top connection 190 may include an adjustment mechanism (not shown), such as a hook-and-loop fastener, a snap-fit ​​connector, etc., to allow for variations in the combined length of the top straps 140 to accommodate different head sizes. The lateral end portions 142 of each top strap are configured to be integrally formed with the bottom strap 150 at the housing or strap connection 170, as will be discussed in further detail below. In use, the connection 170 is located above or directly behind the user's ear.

[0345] The bottom strap 150 has an elongated shape and includes a rear portion 152 and a front portion 162. The rear portion 152 and the front portion 162 are integral and form a single unit. The rear portion 152 includes a section of the bottom strap 150 that extends rearward from the connector 170 and around the occipital region of the user's head, terminating at the rear end portion 154. In use, the ear arch region 160 in the bottom strap 150 curves above the top of the patient's ear, preventing the strap 150 from contacting the ear. The rear end portion 154 is configured to be positioned at or near the center point or central location on the back of the user's head. The rear end portions 154 of the bottom straps on the right side 120 and left side 130 are configured to be connected together via a bottom engagement 192. The bottom joint 192 may include stitching, welding, bonding, overmolding, or any other fastening arrangement, which may be permanent or removable / disconnectable. In some arrangements, the bottom joint 192 may include an adjustment mechanism (not shown), such as a hook-and-loop fastener, a snap-fit ​​connector, etc., to allow for variations in the combined length of the rear portion 152 of the bottom strap 150 to accommodate different sizes of the user's head.

[0346] The front portion 162 of the bottom strap includes a portion of the bottom strap 150 that extends forward from the connector 170, across the user's temple, and toward the user's nose. In some configurations, the front portion 162 of the bottom strap is shorter than one or both of the top strap 140 or the bottom strap portion 152 and terminates at a front end portion 164 of the bottom strap. The front end portion 164 of the bottom strap is configured to include, or at least be attached to, the mask connector 180. The front end portion 164 of the bottom strap includes a female recess portion 166 that engages with the mask connector 180. In some configurations, the mask connector 180 may be press-fitted or overmolded into the front end portion 164 of the bottom strap and into the female recess portion 166. The mask connector 180 may include a clamping or retaining feature configured to connect to the breathing device 110. The mask connector 180 may include a push-in fit, snap-fit ​​fit, or other suitable connector configured to provide a detachable connection to the mask frame 112 of the breathing device 110. In some embodiments, the mask connector 180 may be configured to connect to an adjustment mechanism that provides means for automatically or manually adjusting the size of the bifurcated headband 100. In some configurations, the mask connector 180 may be permanently attached to the mask frame or yoke to form a continuous loop between the headband 100 and the breathing device 110.

[0347] The right side 120 and left side 130 of the forked head strap 100 are formed as essentially two-dimensional (2D) pieces, i.e., they are formed in a flat structure. When the top strap 140 and bottom strap 150 of the right side 120 and left side 130 are joined together, a 3D forked structure is formed (e.g., Figure 1B (As shown). In some configurations, the bifurcated headband 100 is configured such that the 3D bifurcated structure is maintained at all times, at least when the right side 120 and the left side 130 are connected. This 3D structure improves the ease with which the user interacts with the bifurcated headband 100 and the associated breathing device 110, and with wearing or putting them on. Because the bifurcated headband 100 maintains its shape, the straps are less likely to become tangled, and it should be easier for the user to grasp and orient the bifurcated headband 100. In some configurations, the bifurcated headband 100 maintains at least partial or complete separation of the sides 120, 130. In some configurations, the bifurcated headband 100 maintains at least partial or complete separation at the connection 170 of the opposite sides 120, 130 and / or the front portion 162 of the bottom strap.

[0348] The top strap 140 and the bottom strap 150 each include a monolithic plastic core 210 surrounded by and bonded to the outer shell 220. The outer shell 220 can be knitted, woven, braided, crocheted, etc. The monolithic plastic core 210 forms both the top strap 140 and the bottom strap 150. That is, the plastic core 210 is a single unit between the top strap 140 and the bottom strap 150, and throughout the entire forked head strap 100. The outer shell 220 of both the top strap 140 and the bottom strap 150 can be knitted, woven, braided, crocheted, etc., to form a seamless, continuous, and uninterrupted tube. That is, the outer shell 220 can have a seamless and consistent outer surface along the length of both the top strap 140 and the bottom strap 150. The outer shell 220 can be woven from a spool of yarn comprising wool, cotton, nylon, Lycra, spandex, or a blend of natural and / or synthetic materials. In some configurations, the outer casing 220 can be loosely woven, allowing it to extend in length without stretching or tearing the thread. The amount of Lycra within the thread can vary to alter the elasticity of the strap.

[0349] The housing 220 provides a smooth, clean edge finish for the internally molded forked headband 100. That is, the top strap 140 and bottom strap 150 have a consistent shape and form, without seams, thus providing an aesthetically pleasing appearance. Furthermore, the straps 140 and 150 formed by the housing 220 are easier to manufacture. The seamless circular woven tubes eliminate the need for additional stitching or joining steps, reducing manufacturing time and costs. Furthermore, it is easy to produce and form longer, straight woven tubes, which can then be cut to length and shaped during the breakthrough internal molding process described herein. Even further, the housing 220 is easy to place and position within the molding tool. The tubular shape and circular cross-section of the housing 220 are self-supporting and remain open within the molding tool, thus providing an open flow path for the injected material through the housing.

[0350] The outer shell 220 is flexible before the plastic core 210 is inserted, allowing it to be easily positioned within the cavity of the molding tool. The outer shell 220 may be knitted from a soft-textured material, making the top strap 140 and bottom strap 150 comfortable to the touch when in contact with the user's skin. Similarly, the outer shell 220 may have a certain thickness and number of layers, making the top strap 140 and bottom strap 150 comfortable to the touch when in contact with the user's skin. Furthermore, in some configurations, the outer shell 220 may be knitted from a material with moisture-wicking properties to improve the comfort of the split headband 100. Even further, in some configurations, the outer shell 220 may be knitted from a material with tactile properties to reduce or inhibit slippage of the split headband 100 against the user's skin or hair. In some configurations, the outer shell 220 may differ between the top strap 140 and the bottom strap 150. For example, the bottom strap 150 can be made of a material with moisture-wicking properties, while the top strap 140 can be made of a material with tactile properties. Furthermore, in some configurations, the outer casing 220 can be made of different materials along the lengths of the top strap 140 and the bottom strap 150, resulting in different properties in different areas along the lengths of the straps 140 and 150. For example, the top strap 140 and the bottom strap 150 can be different colors.

[0351] The outer shells 220 of both the top strap 140 and the bottom strap 150 are filled with an integral plastic core 210. In some configurations, the plastic core 210 comprises a relatively rectangular cross-section formed of a thermoformed or thermoset plastic material configured to provide the aforementioned 3D structure for the forklift headband 100. The plastic core 210 provides the basis for the overall structure of the forklift headband 100. The plastic composition of the plastic core 210 provides the benefit of a resilient structure capable of conforming to the individual skull geometry of the user while maintaining a pre-formed shape. The plastic core 210 has a width significantly greater than its depth. The illustrated cross-sectional geometry, combined with the material selection, allows the forklift headband 100 to be positioned in a direction orthogonal to its width ( Figure 1A It is flexible in the vertical direction (within the depth) and in the direction orthogonal to the depth ( Figure 1A The headband 100 is relatively inflexible in the horizontal direction. This flexibility in one direction allows the bifurcated headband 100 to conform to the user's head, while providing rigidity in the other direction, thereby stabilizing the breathing device 110 on the user's face and minimizing movement of the breathing device on the user's face.

[0352] The forklift headband 100 can be configured to be substantially inelastic due to, for example, the choice of material. One or more elements of a composite material can provide the forklift headband 100 with substantially inelastic qualities. In a first non-limiting exemplary embodiment disclosed herein, the plastic core 210 is made of a substantially inelastic material (such as, but not limited to, polypropylene or nylon). In embodiments where the forklift headband 100 is intended to withstand small loads, the plastic core 210 may be made of other materials (such as, but not limited to, thermoplastic elastomers (TPE) or silicone). In some embodiments, the plastic core 210 may have a degree of elasticity, and one or both of the housings 220 of both the top strap 140 and the bottom strap 150 may be substantially inelastic. Including a substantially inelastic material in the forklift headband 100 is advantageous because the material reduces or eliminates the possibility of the headband being stretched or pulled too far above the user's head. If the bifurcated headband 100 is pulled too far on the user's head, the breathing device may not be able to be effectively positioned to provide treatment, and uncomfortable forces may be applied to the user's head, which may lead to decreased compliance with treatment.

[0353] Connection part

[0354] Figure 2A and Figure 2B This is a close-up view of the connection between the top strap 140 and the bottom strap 150 at the connecting portion 170. As described above, the plastic core material 210 is a single unit and is positioned within the housing 220 of both the top strap 140 and the bottom strap 150. Figure 3 The top strap 140 and the bottom strap 150 are along... Figure 2B The figure shows a cross-sectional view along line 3-3. As shown, the bottom strap 150 is filled with a plastic core 210, which extends through the outer shell 220 of the bottom strap 150 at the connecting portion 170 and then into the lateral end portion 142 of the top strap to fill the top strap 140. Thus, the outer shells 220 of both the top strap 140 and the bottom strap 150 are joined together by the plastic core 210.

[0355] like Figures 2A to 3As shown, the top strap 140 and bottom strap 150 may have soft edge portions 222 that extend longitudinally along the edges of multiple portions of both the top strap 140 and bottom strap 150. The soft edge portions 222 are part of the unfilled plastic core 210 of the housing 220. Therefore, the soft edge portions 222 provide soft or cushioned edges for the top strap 140 and bottom strap 150, which are not only comfortable against the user's skin but also aesthetically pleasing. As will be described in further detail below, the soft edge portions 222 are formed by crimping the edges of the housing 220 before injecting the plastic core 210, thereby inhibiting or restricting the flow of the plastic core 210 into the multiple portions of the housing 220. The edges of the housing 220 are crimped by a portion of the molding tool adjacent to the mold cavity of the molding tool. The molding tool can press the edges of the top strap 140 and the bottom strap 150 to a depth that varies along the length of the top strap 140 and the bottom strap 150, so that the width of the plastic core material 210 ( Figure 1A The width of the plastic core 210 (vertically) can vary along the length of the top strap 140 and the bottom strap 150. Therefore, the width of the plastic core 210 can be wider in different areas of both the top strap 140 and the bottom strap 150 (such as the connecting portion 170 and the front end portion 164 of the bottom strap) to reinforce those areas and provide additional strength. Similarly, in some configurations, the width of the plastic core 210 can be narrower in certain areas along the length of both the top strap 140 and the bottom strap 150 to provide flexibility in those narrower areas. Those skilled in the art will understand that the shape and geometry of the plastic core can be varied to provide strength and stiffness to the top strap 140 and the bottom strap 150 in desired directions.

[0356] molding tools

[0357] Figure 4 An injection molding tool 300 is shown for opening / closing, configured to form either the right side 120 or the left side 130 of the forked headband 100 in a single injection molding process. In some configurations, the right side 120 and the left side 130 are identical, wherein the injection molding tool 300 can be used to form both sides 120, 130. Figure 4The diagram shows the fully formed bifurcated headband 100 after the injection molding process is completed. The injection molding tool 300 includes a first tool half 310 and a second tool half 320. The first tool half 310 is configured to align with and sit on top of the second tool half 320 to close the injection molding tool 300. The first tool half 310 and the second tool half 320 are substantially symmetrical (i.e., mirror images), therefore, for simplicity, the following discussion will refer to the second tool half 320. Figure 5 As shown, the second tool half 320 includes a top strap cavity 322 and a bottom strap cavity 324. The top strap cavity 322 and the bottom strap cavity 324 are configured to receive the housing 220 of both the top strap 140 and the bottom strap 150. Therefore, the top strap cavity 322 and the bottom strap cavity 324 are arranged in a shape corresponding to the desired shape of the left and / or right side of the forked headband 100. In some configurations, the injection molding tool 300 can be used to form both the right side 120 and the left side 130 of the forked headband 100. In some configurations, the housing 220 is cut to a certain length so as to fit within the strap cavities 322, 324 before the molding tool 300 is closed.

[0358] The connector insert 350 is inserted into the bottom strap front portion 164 of the housing 220. The connector insert cavity 370 is positioned within the second tool half 320 and has a shape corresponding to the connector insert 350. The connector insert 350 and the housing 220 are respectively positioned within the connector insert cavity 370 and the strap cavities 322, 324. When using the housing 220 to form the straps 140, 150 of the forked headband 100, the end of the housing 220 is open or formed as a hollow tube, thereby providing a channel for the plastic core material 210 to be injected into the housing 220. Therefore, the connector insert 350, positioned within the open end of the bottom strap 150, reduces or inhibits the narrowing or closing of the open end of the housing 220. The connector insert 350 includes a pre-formed component that fits inside the open end of the housing 220 and pushes the opening of the housing 220 outward toward the walls of the strap cavities 322, 324 in the first tool half 310 and the second tool half 320. The connector insert 350 has openings (not shown) aligned with flow channels 380, through which a direct flow path is provided for injecting a plastic core material into the housing 220. The connector insert 350 is also configured for use at the bottom strap tip portion 164 (see...). Figure 7An internal (female) connection geometry is formed within the face mask, which connects to an opposing male connector geometry (not shown) on the face mask frame or other face mask components. The connector insert 350 can be made of plastic or metal. If made of plastic, in some configurations, the connector insert 350 can be made of the same plastic as the core, allowing chemical bonding to be formed between the connector insert 350 and the plastic core material during a breakthrough internal molding process. Additionally, the connector insert 350 can be shaped to have additional functionality as a connector (e.g., connector 180) between headband components, adjustment mechanisms, or between the headband and the face mask.

[0359] like Figure 4 and Figure 5 As shown, the flow channel 380 fluidly connects the gate injection point 390, the front and rear end portions 154 and 164 of the bottom strap, and the central end portion 144 of the top strap. Therefore, when the plastic core material 210 is injected into the first tool half 310 and the second tool half 320, the plastic core material 210 is injected into the housing 220 through each of the front and rear end portions 154 and 164 of the bottom strap and the central end portion 144 of the top strap.

[0360] The top strap cavity 322 and the bottom strap cavity 324 have flexible edge clamps 360, which are formed along one or both of the outer edges of the cavities 322 and 324 in the longitudinal direction. The flexible edge clamps 360 are raised areas that protrude into the top strap cavity 322 and the bottom strap cavity 324 in a direction substantially parallel to the closing direction of the injection molding tool 300, such that when the injection molding tool 300 is closed, the top strap cavity 322 and the bottom strap cavity 324 narrow along one or both of the outer edges of the cavities 322 and 324 in the longitudinal direction (i.e., narrowing the outer edges relative to the central region of the cavities 322 and 324). Therefore, the flexible edge clamps 360 clamp or press against the outer edges of the outer shell 220 of both the top strap 140 and the bottom strap 150, thereby forming the flexible edge portion 222. More specifically, the soft-edge clamp 360 presses the edges of the housing 220 together, ensuring that these edges are fully crimped. Therefore, when the plastic core 210 is injected into the housing 220, it does not flow between the crimped edges. This creates a soft or cushioned edge finish on the internally molded bifurcated headband 100 by preventing the internally molded plastic core 210 from filling the housing 220. A portion of each edge of the straps 140, 150 remains empty and soft to the touch to improve patient comfort. In some configurations, the edges of the housing 220 may be narrowed but not fully crimped, allowing a reduced amount of plastic core 210 (relative to the uncrimped portion of the housing 220) to flow between the edges of the housing 220.

[0361] Figure 6 This is a close-up view of the second tool half 320, showing the top strap 140 and the bottom strap 150 positioned relative to each other. As shown, the lateral end portion 142 of the top strap is positioned abutting against or in contact with the housing 220 of the bottom strap 150. That is, the housing 220 of the top strap 140 is placed within the top strap cavity 330 such that the lateral end portion 142 of the top strap abuts against the edge of the housing 220 of the bottom strap 150. As will be described in more detail below, the arrangement of these straps is not limited to having the open end of one strap in contact with the edge of another strap. In some configurations, these straps may have middle portions or non-end portions that abut against each other, through which the straps are joined.

[0362] Molding process

[0363] The process of molding the left 120 or right 130 of the forked head band 100 using injection molding tool 300 includes the following steps: inserting the housing and closing the tool; injecting plastic; and then opening the tool to release the part. In some configurations, these steps are performed in this order; however, in other configurations, the order may be changed and / or additional steps may be included. Such additional steps may be interposed within the steps identified above.

[0364] In at least some embodiments, the process of molding the left side 120 or right side 130 of the forked headband 100 includes the “breakthrough” molding process described below.

[0365] A first length of the housing 220 is inserted into the bottom strap cavity 324 of the second tool half 320 of the injection molding tool 300, the bottom strap cavity being configured to form the bottom strap 150. Similarly, a second length of the housing 220 is inserted into the top strap cavity 322, the top strap cavity being configured to form the top strap 140. The housing 220 can be cut to a length such that it fits snugly within the strap cavities 322, 324. The connector insert 350 is positioned inside the open end of the second length of the housing 220 (i.e., the front end portion 164 of the bottom strap), aligned with the connector insert cavity 370, and then inserted into the connector insert cavity.

[0366] Once the outer shell 220 is aligned within the second tooling half 320, the injection molding tool 300 is closed, completely sealing the strap cavities 322, 324. Thermosetting or thermoforming plastic core material 210 is then injected into the strap cavities 322, 324 of the mold cavity via the gate 390 and runner 380. More specifically, the plastic core material 210 is injected into the injection molding tool 300 through the gate 390. Generally, the plastic core material 210 follows the path of least resistance to fill the strap cavities 322, 324. The plastic core material 210 travels through the runner 380 until it reaches the open end of the outer shell 220. The plastic core material 210 enters the central end portion 144 of the top strap, the rear end portion 154 of the bottom strap, and the front end portion 164 of the bottom strap (via connector insert 350). Reference Figure 6When the outer shell 220 in the bottom strap cavity 324 is filled with the plastic core material 210 (i.e., since the outer shell is filled from both open ends, in contrast to the outer shell 220 in the top strap cavity 322, which is initially filled at one end), the plastic core material 210 will break through, penetrate, and squeeze through the wall of the outer shell 220 of the bottom strap 150 at the connection 170. The plastic core material 210 penetrating the wall of the bottom strap 150 enters the open end of the outer shell 220 of the top strap 140 (i.e., the lateral end portion 142 of the top strap), connecting with the plastic core material 210 entering the opposite end of the outer shell 220 of the top strap 140 (i.e., from the central end portion of the top strap) until the outer shell 220 of the top strap 140 is filled with the plastic core material 210. Once the outer shell 220 of the straps 140 and 150 is filled, a period of time is allowed for the plastic core material 210 to solidify, cool, and harden. Once solidified, the injection molding tool 300 is opened and the part is removed. Thus, the integral plastic core 210 can be formed within the top strap 140 and bottom strap 150 together with a seamless and uniform outer shell 220 of the top strap 140 and bottom strap 150. That is, the integral plastic core 210 of the top strap 140 and bottom strap 150 can be formed by pushing the plastic core 210 through the outer shell 220 of the bottom strap 150 into the top strap 140. In other words, forming the integral plastic core 210 within the top strap 140 and bottom strap 150 has the beneficial effect of a breakthrough internal molding process when both straps have seamless and uniform outer shells 220, and one strap is attached to the middle or non-end portion of the seamless adjacent strap. In other embodiments, the plastic core 210 penetrates and breaks through the outer shell 220 before the outer shell 220 and strap cavity are filled with the plastic core 210. This may occur, for example, in the following situations: the unsupported portion of the housing 220 is closer to the injection point, the plastic core 210 has a low density or low viscosity, the housing 220 has a low linear density, and / or the unsupported portion is larger than the supported area.

[0367] The plastic core 210 penetrates and breaks through the wall of the outer shell 220 of the bottom strap 150 because it follows the path of least resistance to fill the strap cavity. When the outer shell 220 is supported, abuts against, or presses against the surface of the injection molding tool 300, the injected plastic core 210 will flow in the less restricted direction until the cavity within the injection molding tool 300 is filled. (Reference) Figure 5Once the bottom strap cavity 324 is filled with the plastic core 210, the material flows into the top strap cavity 322 in the direction of least restriction because the outer shell 220 of the bottom strap 150 is not supported by the surface of the bottom strap cavity 324, does not abut against or press against the surface of the bottom strap cavity. With the outer shell 220 not pressing against the surface of the injection molding tool 300 (i.e., not supported by that surface), the injected plastic core 210 will fill the cavity by penetrating the outer shell 220. Penetration of the outer shell 220 can occur due to the plastic core 210 flowing through it. That is, the threads of the outer shell 220, under the pressure of the injected plastic core 220 (i.e., when unsupported), shift or elastically deform (i.e., depending on the material of the outer shell 220). Therefore, the plastic core 220 will flow through and squeeze through the gaps created between the shifted or elastically deformed threads of the outer shell 220. In some configurations, the pressure on the plastic core 220 within the housing 220 can cause the threads of the housing 220 to tear or break at unsupported portions of the housing 220. Tearing or breaking the housing 220 can create a hole within the housing 220 through which the plastic core 210 can penetrate and break to flow into and be pushed into adjacent straps.

[0368] Whether the plastic core 210 breaks through or penetrates the outer shell 220 can depend on the injection molding parameters of the outer shell 220 and the textile properties. Regarding the injection molding parameters, whether a breakthrough or penetration occurs can depend on pressure, injection speed, the location of the injection point and the length of the injection path, the location of the unsupported area and the relative size of the unsupported area relative to the supported area, and the material properties of the injected plastic core 210. Regarding the textile properties of the outer shell 220, whether penetration occurs can depend on the thread count, thread size, elasticity, linear density, denier, thread strength, etc., of the outer shell 220. Breakthrough or penetration from the outer shell 220 can occur at higher pressures. In at least some embodiments, elasticity alone may or may not affect penetration. As a non-limiting example, a highly elastic outer shell with a high thread count can deform / stretch when not supported by the molding tool 300 (i.e., in contrast to allowing penetration). However, as the outer shell 220 stretches, gaps or spaces between the threads will begin to form to provide a path for the plastic core to penetrate the outer shell 220. Therefore, the injection molding parameters and textile properties can be varied based on the desired characteristics of the forked headband 100 and the ability to manufacture the forked headband 100 using a breakthrough in-mold process.

[0369] Alternative Arrangements

[0370] Figure 8A A second tool half of the injection molding tool 400 is shown, which has an alternative internal molding strap cavity arrangement for use in injection molding. Figure 8BThe connecting part shown incorporates multiple straps 410, 412, and 414. For comparison, Figure 8B A T-shaped connector 420 is shown, which is connected to... Figures 1A to 7 The connecting part 170 is similar. Figure 8B An alternative connection portion, in the form of an X-shaped connector 422, is also shown. As described above and in Figure 8B As shown, the T-shaped connector 420 is formed by positioning the open end of the housing of strap 410 in contact with the edge of the housing of strap 412 (i.e., with the molding tool providing the strap cavities with corresponding arrangements). In contrast, the X-shaped connector 422 is formed by overlapping the non-open end portions of the housings of straps 410, 414. In other words, straps 410, 414 are positioned in an overlapping orientation such that straps 410, 414 abut against each other at a location between their open ends, forming the X-shaped connector 422. In an alternative embodiment, one of the straps 414 is formed by two strap portions that are connected to another strap 410 by connecting the respective ends of each of the two strap portions to the other strap 410, thereby forming the X-shaped connector. In these embodiments, the injection molding tool 400 includes correspondingly formed strap cavities for supporting straps 410, 414. Figure 8A and Figure 8BThe positioning of gate 430, runner 432, and injection point 434 is shown, through which plastic core material 424 is injected into injection molding tool 400 to fill straps 410, 412, and 414. Injection point 434 is positioned on one open end of strap 410 and is effectively positioned on the opposite open end of strap 410 (i.e., passing through strap 412 via injection point 434). In the illustrated configuration, the open end of strap 414 is not fluidly connected to injection points 430 except at other locations via X-shaped connector 422. When plastic core material 424 is injected into injection molding tool 400, it enters the open end of strap 410 and travels toward X-shaped connector 422. In an embodiment where one of the straps 414 is formed by two strap portions connected to another strap 410, when the strap 414 begins to fill, the plastic core material 424 follows the path of least resistance and penetrates the edge of the outer shell of the strap 410, and then penetrates the open end of the outer shell of the strap 414. That is, the strap cavity of the strap 414 is empty, thereby providing a path of least resistance for the plastic core material 424. Therefore, the outer shell of the strap 414 is filled with the plastic core material 424, which enters the strap 414 through the X-shaped connector 422. Those skilled in the art will understand that the above configuration is not limited to the injection point located at the open end of one of the straps when the X-shaped connector 422 is formed. In some configurations, the X-shaped connector 422 may be formed such that both straps have at least one injection point at their ends.

[0371] As shown in the figure, the T-shaped connector 420 and the X-shaped connector 422 can be used in combination to form various headband shapes and structures with multiple straps. Multiple strap connectors / joints can be formed in a single injection molding step. This type of strap configuration can be used in four-point headband structures typically used in conjunction with nose shields and full-face masks.

[0372] Figure 9AAn alternative internally molded strap arrangement is shown, having straps 520 connected together by integrally formed connecting members 530 positioned between the straps 520. The connecting members 530 are formed of a plastic core 510 that penetrates the wall of the outer shell of the straps 520 and enters another region of the mold cavity. That is, the injection molding tool (not shown) may have cavities corresponding to the connecting members 530, which are fluidly connected to the strap cavities of the straps 520. Therefore, when molten plastic core 510 is injected into the injection molding tool, the plastic core 510 enters the outer shell of the straps 520 at injection point 540. As the straps 520 begin to fill, the plastic core 510 follows the path of least resistance and penetrates the wall of the outer shell (i.e., at the unsupported portion of the outer shell adjacent to the cavity corresponding to the connecting member 530), allowing the plastic core to enter and fill the cavity corresponding to the connecting member 530. In some configurations, the plastic core 510 may be an elastomeric material, allowing the connecting member 530 to be stretched. Additionally, in such embodiments, the outer shell may restrict the stretching of the plastic core 510.

[0373] Figure 9B An alternative internally molded strap arrangement is shown, featuring straps 520 connected together by integrally formed fiber web portions 532 positioned between the straps 520. Figure 9A Similar to the connecting member 530, the injection molding tool (not shown) may have a cavity corresponding to the fiber web portion 532, which is fluidly connected to the strap cavity of the strap 520. The cavity corresponding to the fiber web portion 532 may have a depth shallower than the depth of the strap cavity of the strap 520. Therefore, when molten plastic core material 510 is injected into the injection molding tool, the plastic core material 510 enters the shell of the strap 520 at the injection point 540. As the strap 520 begins to fill, the plastic core material will follow the path of least resistance and penetrate the wall of the shell (i.e., at the unsupported portion of the shell adjacent to the cavity corresponding to the fiber web portion 532), so that the plastic core material enters and fills the cavity corresponding to the fiber web portion 532. In some configurations, the plastic core material 510 may be an elastomeric material, allowing the fiber web portion 532 to be stretched. Additionally, in such embodiments, the shell may restrict the stretching of the plastic core material 510.

[0374] Figure 10AAn alternative internally molded strap arrangement is shown, featuring a chamfered connection 620 that connects a chamfered strap 622 to an adjacent strap 624 or headband portion. The textile shell of the chamfered strap 622 has a width that extends, opens, and curves radially outward toward the chamfered connection 620 with the adjacent strap 624 or headband portion to provide a smooth transition between straps 622 and 624. In other words, the width or diameter of the textile shell of the chamfered strap 622 increases along the length of the chamfered strap 622 toward the end that abuts against the adjacent strap 624. Therefore, the chamfered connection 620 provides a larger connection area with the textile shell of the adjacent strap 624, which can provide increased strength and aesthetic appeal compared to a non-chamfered connection. Figure 10B An injection molding tool 610 for forming the chamfered connection 620 is shown. As shown, the injection molding tool 610 has a chamfered strap cavity 612 with a shape corresponding to the shape of the textile shell of the chamfered strap 622. In the illustrated embodiment, the textile shell of the chamfered strap 622 is preformed from two layers of microfibers that have been sewn together and turned inside out to form a tube that bends outward at an open end. The adjacent strap 624 has a shell similar to that of the previously described embodiment. Furthermore, the adjacent strap 624 is positioned within a correspondingly formed strap cavity 614 that abuts against the open end of the chamfered strap 622. Therefore, a plastic core 630 is injected into the open end of the chamfered strap 622 and / or the adjacent strap 624. The plastic core material 630 penetrates the wall of the outer shell of the adjacent strap 624 at the chamfered connection 620, so that the plastic core material 630 is integrally formed within the chamfered strap 622 and the adjacent strap 624. As shown in the figure, the textile outer shell of the chamfered strap 622 can abut another internally molded strap portion (i.e., the outer shell of the strap 624, such as...) Figure 10B (As shown) or adjacent to the uncovered plastic core material 630, such as Figure 10A As shown. In some configurations, the housing of the chamfered strap 622 can be made into a single piece of woven tubing, which is woven into a shape including the chamfered ends.

[0375] Figures 11A to 11E The internal molded strap arrangement is shown, which has a molded texture embossed into the strap. Figures 11A to 11C The binding strap 720 is shown, which has multiple square diamond-shaped indentations 730 arranged in rows along the length of the binding strap 720. (See image below.) Figure 11C What is shown is along Figure 11BThe cross-section of line 11C-11C shows indentations 730 formed on both sides of the strap 720, aligned to form a thin region 732 within the strap 720. The thin region 732 can provide a degree of stretch or elasticity to the plastic core 710. This flexibility can facilitate allowing the closed-loop headband to move over the patient's head or improve the patient's perception of the semi-rigid headband. Additionally, the textured finish of the strap 720 can improve the aesthetic appearance of the headband and its tactile appeal. That is, the strap 720 can appear less rigid and more comfortable. In some embodiments not shown, the indentations 730 can form interrupted areas where there is no plastic core 710 between the layers of the outer shell 712. These interrupted areas can improve the breathability of the strap 720, thereby improving user comfort. Figure 11D and Figure 11E Multiple hexagonal indentations 730 are shown, spaced apart in a honeycomb pattern along the length of the strap 720. It should be understood that the indentations 730 are not limited to rhomboid or hexagonal shapes, but can include various shapes, sizes, positions on the strap, geometric structures, combinations of shapes, etc. Figure 11D and Figure 11E In the center, the plastic core and honeycomb pattern do not extend all the way to the edge of the 720's outer shell. This provides a soft edge to improve user comfort.

[0376] The indentation 730 is formed during the breakthrough internal molding process in a manner similar to forming a soft edge of a strap. That is, the strap cavity of the strap 720 may include a series of protrusions on the first and second tool halves. These protrusions extend into the strap cavity and have a shape corresponding to the indentation 730. When a plastic core material is injected into the strap 720, these protrusions mold the shape of the indentation into the plastic core material.

[0377] Figures 12A to 13D The internal molded strap arrangement of the forked headband 1100 is shown, which has attachment members that increase the bonding strength at the joints between the straps. Figures 1A to 7 The forked headband shown in the image is similar to the 100. Figures 12A to 13D The forked headband 1100 includes a top strap 1140 and a bottom strap 1150. Similarly, the open end portion of the top strap 1140 is coupled to the non-end portion of the bottom strap 1150. Figures 1A to 7 Compared to the bottom strap 150, the bottom strap 1150 includes an attachment member 1156 projecting outward from the wall of the housing of the bottom strap 1150. As will be described in more detail below, the top strap 1140 is overmolded onto the attachment member 1156 to form a permanent connection between the top strap 1140 and the bottom strap 1150.

[0378] The forked headband 1100 is formed through a two-step internal molding process. That is, the bottom strap 1150 and attachment member 1156 are internally molded using a breakthrough internal molding process, and then the top strap 1140 is internally molded onto the attachment member 1156 and the bottom strap 1150. Figure 12A and Figure 12B The first step of a breakthrough internal molding process for forming the forked headband 1100 is illustrated. As shown, the bottom strap 1150 and attachment member 1156 are formed by positioning the housing 1220 of the bottom strap 1150 into the bottom strap cavity 1324 of the first molding tool 1320. The attachment member 1156 is formed of a plastic core 1210 that has penetrated or broken through the wall of the housing 1220 of the bottom strap 1150, similar to the penetration and breakthrough techniques described above. For the sake of brevity, further discussion will be omitted. Figure 13A and 13D The second step of the internal molding process for forming the forked headband 1100 is illustrated. As shown, the fully formed bottom strap 1150 is positioned within the bottom strap cavity 1326 of the second molding tool 1322. The housing 1220 of the top strap 1140 is positioned within the top strap cavity 1328 of the second molding tool 1322. The open end of the top strap 1140 is positioned above the attachment member 1156 of the bottom strap 1150. That is, the housing 1220 of the top strap 1140 is placed in the second molding tool 1322 such that the housing 1220 of the top strap 1140 covers and / or surrounds the attachment member 1156. The open end of the housing 1220 of the top strap 1140 abuts the soft edge 1222 of the bottom strap 1150. The outer shell 1220 of the top strap 1140 is filled with a plastic core 1210, which enters the second molding tool 1322 via an injection point 1390. During injection, the plastic core 1210 within the outer shell 1220 of the top strap 1140 is molded onto and / or around the attachment member 1156 to form a permanent connection between the top strap 1140 and the bottom strap 1150. Additionally, at the connection 1170 between the top strap 1140 and the bottom strap 1150, a chemical and / or mechanical connection is formed between the attachment member 1156 and the plastic core. The attachment member 1156 may include a mechanical interlocking structure providing a partial interlocking hole 1157. Figures 13A to 13B ) or interlock hole 1158 ( Figures 13C to 13DThe plastic core 1210 within the housing 1220 of the top strap 1140 passes through the hole. Mechanical interlocking can increase the surface area of ​​the bottom strap 1150 at the connection 1170, to which the top strap 1140 can be chemically or mechanically bonded. Additionally, the plastic core 1210 passing through the interlocking holes 1157 and 1158 can provide an interlocking mechanical connection between the plastic cores 1210 of the top strap 1140 and the bottom strap 1150. In some configurations, the top strap 1140 can be formed using an internal molding process and attached to the bottom strap 1150. That is, the bottom strap 1150 and the attachment member 1156 can be formed using an alternative strap forming technique, after which the top strap 1140 can be overmolded onto the attachment member 1156 using an internal molding process.

[0379] Figures 14A to 14D An alternative strap arrangement for the forklift headband 1400 is shown, which has a strap housing with sealed ends. The forklift headband 1400 has a top strap 1402 and a bottom strap 1404, which are similarly arranged to have Figures 1A to 7 The top strap 140 and bottom strap 150 are bifurcated headbands 100. In addition, the top strap 1402 and bottom strap 1404 are connected at the connection 1470 using a breakthrough internal molding process, which is similar to the connection of the top strap 140 and bottom strap 150 at the connection 170.

[0380] Figure 14A A housing 1410 with a top strap 1402 is shown, having a sealed open end portion 1430. The sealed open end portion 1430 is formed by cutting the ends of the housing 1410 with a hot cutter. In the case where the housing is made of synthetic textile, cutting the housing 1410 with a hot cutter melts the edges of the housing 1410, which seals or binds together any loose ends of the individual threads / yarns that would otherwise be exposed and / or worn after the housing 1410 is cut to a certain length. Therefore, when the sealed open end portion 1430 is connected to the bottom strap 1404, the connection 1430 has no loose or worn individual threads / yarns, which improves the aesthetics of the connection 1470 and the forked head strap 1400. In addition, the sealed open end portion 1430 can reduce the excessive flash formed around the connection 1470 on the outside of the housing 1410 after the plastic core material 1420 penetrates the wall of the housing during the breakthrough internal molding process. In other words, the sealed open end portion 1430 provides a substantially sealed edge or surface (i.e., the worn open end portion relative to the housing 1410 of the bottom strap 1402) that contacts the housing 1410 of the bottom strap 1402, which prevents or inhibits the leakage of the plastic core material 1420 from the housing 1410 of the top strap 1402 at the sealed open end portion 1430. Figure 14CA connection 1470 is shown formed between the sealed open end portion 1430 of the top strap 1402 and the edge of the housing 1412 of the bottom strap 1404. Figure 14D The top strap 1402 and the bottom strap 1404 are shown along... Figure 14C The cross-section of line 14D-14D is shown. The top strap 1400 and the bottom strap 1402 are joined together using the breakthrough internal molding technique discussed above. In an alternative configuration, the open ends of the top strap 1402 can be overmolded prior to injection molding to seal the ends of the top strap 1402.

[0381] In another embodiment, the sealed open end portion can be formed as follows: the housing is placed in a heat-sealing machine, and then the outer portion of the housing is sealed / melted without cutting with the heat-sealing machine. Next, the housing is cut in the middle of the sealed area (i.e., after the sealed area has cooled), thereby forming the open end. Although the inner walls of the housing are not sealed or fused together, the individual yarns are fused to the outer side of the housing (i.e., the outer wall), thereby securing the loose threads of the individual yarns. This not only provides a clean and aesthetically pleasing effect but also prevents or inhibits leakage of the plastic core material from the housing at the sealed open end portion.

[0382] Figures 15A to 15D A forked headband 1500 with a filament core 1550 is shown, the core end portion 1512 of which is anchored to a plastic core 1510 within a bottom strap 1502. The filament core 1550 can be used in conjunction with a conversion locking arrangement as disclosed in U.S. Patent Application 14 / 856,193, which is incorporated herein by reference. The filament core 1550 and the conversion locking arrangement provide a length adjustment arrangement for adjusting the length and tension of the bottom strap of the headband to allow the face mask interface to be loose or taut against the user's face. For example, in some configurations, a locking mechanism can engage the filament core to adjust the effective length of the bottom strap.

[0383] The forked head strap 1500 has a top strap 1502 and a bottom strap 1504, which are similarly arranged to have Figures 1A to 7 The top strap 140 and bottom strap 150 are bifurcated headbands 100. In addition, the top strap 1502 and bottom strap 1504 are connected at the connection 1570 using a breakthrough internal molding process, which is similar to the connection of the top strap 140 and bottom strap 150 at the connection 170.

[0384] like Figure 15AAs shown, the top strap 1502 is joined to the bottom strap 1504 at the connection 1570. The top strap 1502 and the bottom strap 1504 are joined via a formed plastic core 1510, which is integrally formed within the housing 1520 of both the top strap 1502 and the bottom strap 1504 using the breakthrough in-mold molding technique discussed above. Similarly, the top strap 1502 and the bottom strap 1504 have soft edges 1522. As shown, the filament anchoring portion 1552 of the filament core 1550 is positioned within the core end portion 1512 of the plastic core 1510. The filament core 1550 is secured within the core end portion 1512 and anchored to the core end portion at a location in front of the connection 1570 (i.e., in front of the user's ear). In some configurations, the filament core 1550 is joined to the plastic core 1510 during the breakthrough in-mold molding process. The filament core 1550 is surrounded by the outer shell 1520 of the bottom strap 1504, but is not attached to the outer shell. That is, the filament core 1550 is not attached to the outer shell 1520 between the core end 1512 and the open end 1524 of the outer shell 1520. Therefore, the outer shell 1520 can move independently above the filament core 1550, and is effectively non-extendable. Furthermore, similar to previous embodiments formed using a breakthrough internal molding technique, the plastic core material 1510 is bonded to both the top strap 1502 and the bottom strap 1504 of the outer shell 1520.

[0385] like Figure 15B As shown, the bottom strap 1504 and Figures 1A to 7 The difference in the bottom strap 150 is that the outer shell 1520 of the bottom strap 1504 is longer in order to cover, surround, and conceal a portion of the filament core 1550. Concealing the filament core 1550 improves the aesthetic appearance of the headband. The filament core 1550 extends forward from the core end portion 1512 of the bottom strap 1504, and its length is greater than the stretched or extended length of the outer shell 1520 of the bottom strap 1504, such as... Figure 15B and Figure 15C As shown. Figure 15B The unstretched length of the housing 1520 with bottom strap 1504 is shown. Figure 15C The diagram shows the outer shell 1520 of the bottom strap 1504 stretched to its maximum length, while a portion of the filament core 1550 still extends further beyond the maximum length of the outer shell 1520. Therefore, the outer shell 1520 of the bottom strap 1504 is configured to conceal the filament core 1550 at a series of locations between it and a locking mechanism (not shown). The stretched and unstretched lengths of the outer shell 1520 can vary depending on the size of the headband and the desired range of adjustability.

[0386] Figure 15DA close-up view of the outer shell 1520 of the bottom strap 1504 in a stretched state is shown. In a preferred embodiment, the outer shell 1520 of the second strap 1504 is woven and comprises inelastic yarns with linear elastic elements incorporated therein. The outer shell 1520 is capable of extending and retracting independently of the filament core 1550. Figure 15D As shown, when extended, the outer shell 1520 of the bottom strap 1504 necks or narrows when stretched from the core end portion 1512, as shown in the necking region 1526. The yarns of the outer shell 1520 are aligned, thereby limiting the extension length of the braid. The filament core 1550 is longer than the extension length of the braid. When no force is applied to the braid, the linear elastic element of the outer shell 1520 retracts the braid.

[0387] Figure 16A A split headband 2000 is shown, featuring top straps 2140 on the right side 2120 and the left side 2130, which are connected by a button and hole size adjustment system 2200. The button and hole size adjustment system 2200 may resemble a snap-fit ​​button and hole adjustment system commonly used in baseball caps, but it is integrally molded as part of the split headband 2000. The size adjustment system 2200 includes multiple holes 2210 extending through the top strap 2140 on the left side 2130 (in... Figure 16A (Not visible in the middle), and a plurality of buttons 2220 protruding from the upper surface 2222 of the top strap 2140 on the right side 2120. The positioning of the plurality of holes 2210 and the plurality of buttons 2220 relative to the right side 2120 and the left side 2130 can be interchanged, such that the plurality of buttons 2220 extend from the top strap 2140 on the left side 2130, while the plurality of holes 2210 extend through the top strap 2140 on the right side 2120.

[0388] Figure 16B This is a close-up cross-sectional view of the button and hole size adjustment system 2200. That is to say, Figure 16B A button 2220 extending through hole 2210 is shown. Regarding features not specifically discussed, the split headband 2000 may be identical or similar to other headbands disclosed herein. That is, the split headband 2000 has a top strap 2140 and a bottom strap 2150, which are similarly arranged to have… Figures 1A to 7 The top strap 140 and bottom strap 150 have forked headbands 100. Furthermore, the top strap 2140 and bottom strap 2150 are connected at the connection 2170 using a breakthrough internal molding process, similar to the connection of the top strap 140 and bottom strap 150 at the connection 170. That is, the top strap 2140 and bottom strap 2150 are formed from a shell 2180 filled with a monolithic plastic core material 2190.

[0389] Figures 16C to 16D The process of opening / closing the injection molding tool 2300, configured to form the button 2220 of the hole size adjustment system 2200, is demonstrated. For simplicity, Figure 16C A portion of both a first tool half 2310 and a second tool half 2320 of an injection molding tool 2300 for forming a single button 2220 is depicted. The configuration of the molding tool 2300 and the process for forming multiple buttons 2220 are substantially similar to the process for forming a single button 2220. Furthermore, the first tool half 2310 and the second tool half 2320 are similar to... Figures 1A to 7 The first tool half 310 and the second tool half 320 are included, and a strap cavity is included for breakthrough internal molding of the plastic core material within the top and bottom straps. In other words, the plurality of buttons 2220 of the hole size adjustment system 2200 can be formed during the breakthrough internal molding process for injecting the plastic core material 2190 into the top strap 2140 and the bottom strap 2150 (i.e., in a single injection molding process).

[0390] Figure 16C A fully formed button 2220 protruding from the upper surface 2222 of the top strap 2140 is shown. A first tool half 2310 and a second tool half 2320 have strap cavities 2312 and 2322, respectively, within which the outer shell 2180 of the top strap 2140 is received and injection-formed using a plastic core material 2190. The first tool half 2310 also includes a button cavity 2314 fluidly connected to the strap cavities 2312 and 2322, having a shape corresponding to the button 2220, which is cylindrical in the illustrated embodiment. The button 2220 and the corresponding button cavity 2314 are not limited to a cylindrical shape. Those skilled in the art will also understand that the techniques used to form multiple buttons 2220 can be used to form alternative features (e.g., raised grips, trademarks, connector portions, etc.) on any surface of the strap.

[0391] Figure 16D This demonstrates that during the process of forming button 2220, the first tool half 2310 and the second tool half 2320 move along... Figure 16CThe cross-section of line 16D-16D is shown. As shown in step 1, the outer shell 2180 is positioned within the strap cavities 2312, 2322. A portion of the outer shell 2180 is not supported by the first tool half 2310, wherein the button cavity 2314 is connected to the strap cavity 2312. As shown in steps 2 and 3, when the strap cavities 2312, 2322 are filled with the plastic core material 2190, the outer shell 2180 is pushed into the button cavity 2314 by the plastic core material 2190. As shown in step 4, when the outer shell 2180 reaches its limit for accommodating the plastic core material 2190, the plastic core material 2190 will break through the outer shell 2180 due to the presence of remaining cavities to be filled (i.e., the button cavity 2314). In other words, when the outer shell 2180 is filled with the plastic core 2190 in an area of ​​the outer shell 2180 that is not supported (e.g., not supported by the button cavity 2314 in the illustrated embodiment), the plastic core 2190 penetrates and breaks through the outer shell 2180, then fills the button cavity 2314. Similar to the breakthrough internal molding process described above, the threads of the outer shell 2180 can be displaced or elastically deformed under the pressure of the injected plastic core 2190. This displacement or elastic deformation can create gaps between the threads, through which the injected plastic core 2190 can flow into the button cavity 2314. In some configurations, the threads of the outer shell 2180 can be torn, creating a hole through the outer shell 2180, through which the injected plastic core 2190 can flow into the button cavity 2314.

[0392] In other embodiments, the plastic core 2190 penetrates and breaks through the housing 2180 before the housing 2180 and the strap cavities 2312, 2322 are filled with the plastic core 2190. This may occur, for example, when the unsupported portion of the housing 2180 is closer to the injection point, the plastic core 2190 has a low density or low viscosity, the housing 2180 has a low linear density, and / or the unsupported portion is larger than the supported area.

[0393] Figure 17An adjustable strap arrangement with adjustable and usability features formed by a breakthrough internal molding process is demonstrated. The arrangement includes a first strap 3110 and a second strap 3120. The first strap 3110 includes a breakthrough end loop 3130 configured to receive the second strap 3120. The second strap 3120 is received within the end loop 3130 and folded rearward, providing a fastening arrangement for removably fastening the free end of the second strap 3120. The second strap 3120 includes a breakthrough end or gripping tab 3140. In at least one embodiment, the second strap 3120 includes an inner surface 3122 and an outer surface 3124, each with a different visual or tactile configuration. When the second strap 3120 is folded rearward and fastened, the portion of the strap fed through the end loop 3130 of the second strap 3120 is exposed on the inner surface 3122. This provides visual and / or tactile indication of the adjusted length.

[0394] Figure 18 A non-limiting exemplary embodiment of a headband 3200 formed according to the currently described internal molding process and / or breakthrough process is shown. The headband 3200 includes a lower strap 3210, a middle strap 3220, and a vertical or top strap (hereinafter referred to as a "vertical strap") 3230. The lower strap 3210 extends from a patient interface (not shown), passes below the user's ear, wraps around the back of the user's head, passes below the user's other ear, and finally reaches the patient interface. The middle strap 3220 extends from the patient interface, passes above the patient's ear, wraps around the back of the headband 3200, passes above the user's other ear, and finally reaches the patient interface. The vertical strap 3230 extends from the lower strap 3210 at a point in front of the user's ear, passes above the top of the user's head, and finally reaches a point in front of the user's other ear.

[0395] exist Figure 18 In the illustrated embodiment, the lower strap 3210 is a continuous strap with a continuous outer shell. In other words, the outer shell of the lower strap 3210 is uninterrupted prior to the internal molding and / or breakout process. After the internal molding breakout process, the lower strap 3210 forms a breakout connection. It should be noted that the continuous outer shell or strap may include pre-formed openings that allow the injected material to be exposed.

[0396] like Figure 18 As shown, the vertical strap 3230 is a continuous strap because it is formed from a continuous or uninterrupted outer shell. After the internal molding breakthrough process, the end portions 3232 of the outer shell of the vertical strap 3230 are connected by breakthrough connectors and internally molded to the lower strap 3210.

[0397] The central strap 3220 is a segmented strap. In other words, the central strap 3220 is formed from multiple housings or segmented housings. The segmented housings are connected to other straps during the internal molding process. Figure 18 In the illustrated embodiment, the middle strap 3220 includes a front portion housing 3222, each of which is connected at a breakout connection to a vertical or top strap 3230, which is vertically spaced from the lower strap 3210 and positioned above the user's ear. The middle strap 3220 further includes a rear portion housing 3224, the end of which is connected during an internal molding breakout process to either the vertical or top strap 3230, also positioned above the user's ear.

[0398] The instruction manual will now focus on discussing Figures 19 to 42 The following are non-limiting exemplary embodiments. For simplicity, the additional features introduced in the corresponding figures will be described in detail. Therefore, features or configurations previously described may not be included every time. In addition, features in the following non-limiting exemplary embodiments can be combined with any of the foregoing non-limiting exemplary embodiments, as long as they can be combined.

[0399] Figure 19 A headband 4100 formed using internal molding and / or a breakthrough process is shown. The headband 4100 includes a continuous lower strap 4110 and a continuous middle strap 4120. A vertical strap 4130 is formed from a breakthrough joint above the user's ear, starting at the apex 4124 of the middle strap 4120. In front of the ear, a connecting strap 4140 formed by a breakthrough joint exists between the lower strap 4110 and the middle strap 4120. The rear portions 4112 of the lower strap 4110 and the rear portions 4122 of the middle strap 4120 converge. A breakthrough fiber mesh portion 4150 connects the rear portions 4112 of the lower strap 4110 and the rear portions 4122 of the middle strap 4120. In some configurations, the vertical strap 4130 and the breakthrough fiber mesh portion 4150 may be formed as a single, integral unit.

[0400] Figure 20 Another headband 4200 is shown, formed using an internal molding and / or breakthrough process. The headband 4200 includes a continuous lower strap 4210 and a combined continuous middle vertical strap 4220. An ear loop 4230 is provided around the user's ear. The lower strap 4210 is attached to the ear loop 4230 along its lower portion 4232. The continuous middle vertical strap 4220 is attached along the upper portion 4234 of the ear loop 4230. Figure 21 The headband 4300 is shown, which is related to... Figure 18The headband 3200 shown is similar, but its fiber mesh portion 4350 connects the rear portion 4312 of the lower strap 4310 and the rear portion 4322 of the middle strap 4320.

[0401] Figure 22 A headband 4400 is shown, comprising a continuous lower strap 4410 extending below the user's ear, then vertically upward, behind the user's ear, and forward above the user's ear to form part of a periauricular loop. A continuous vertical strap 4430 extends from the lower strap 4410 at a portion in front of the ear, forming the remainder of the periauricular loop. A middle strap 4420 is connected to the vertical strap 4430 via a breakaway connector. The lower rear portion 4412 of the lower strap 4410 is connected by a rear panel 4440.

[0402] Figure 23 The headband 4500 is shown, and the headband is... Figure 21 The headband 4300 shown is similar, however it has a smaller fiber mesh portion 4550 that connects the lower strap 4510 to the middle strap 4520.

[0403] Figure 24 A headband 4600 is shown, comprising a continuous lower strap 4610 and a combined continuous middle vertical strap 4620. The headband 4600 further includes a combined continuous upper rear strap and a second vertical strap 4630. A mesh portion 4650 extends between the first vertical strap 4620 and the second vertical strap 4630, and between the rear portion 4612 of the continuous lower strap 4610 and the upper rear strap 4630. The mesh portion 4650 also forms a periauricular ring around the ear. That is, the mesh portion 4650 has a hole within which the ear can be positioned.

[0404] Figure 25 and Figure 26 Two examples of a headband 4700 are shown, which has a lower strap 4710 and a middle strap 4720 in the form of a closed loop structure formed by a continuous outer shell. The lower strap 4710 and the middle strap 4720 form part of an ear loop 4770. A fiber mesh portion 4740 extends between the lower strap 4710 and the middle strap 4720 to form a front portion 4772 of the ear loop 4770. A vertical strap 4730 is formed by a fiber mesh portion extending between the upper portions 4766 and 4776 of the right ear loop 4760 and the left ear loop 4770. A rear portion 4780 of the headband 4700 is formed by a rear fiber mesh portion 4750 extending between the lower rear portions 4764 and 4774 of the right ear loop 4760 and the left ear loop 4770.

[0405] Figure 27 and Figure 28 Two examples of a headband 4900 are shown, which has a provided quilted fabric or material 4910 attached to the portion of the headband 4900 that comes into direct contact with the user's skin or hair (e.g., on the user's face or the back of the user's neck). Similar to a down comforter, the quilted material 4910 is not only soft but also provides cushioning, thus improving the comfort of the headband 4900 and making the user want to wear it to bed. The quilted material 4910 can be sewn or welded to the internal molded straps or fiber mesh portion of the headband 4900. The various configurations disclosed are not limited to quilted materials but can include fabrics and textiles with a variety of material properties, such as, but not limited to, softness, padding, breathability, moisture absorption, and a tight / sticky texture.

[0406] Figure 29 A headband 5100 is shown, comprising a vertical strap 5110 and a neck strap 5120 formed of a foam-Lycra laminated material such as Breath-o-prene. Breath-o-prene allows air to pass through the straps and wicks away sweat from the skin, enhancing comfort and conformability. Additionally, Breath-o-prene provides padding to the straps to reduce pressure points on the user's head. The vertical strap 5110 includes a first strap 3110 and a second strap 3120. The first strap 3110 includes a break-through end loop 3130 configured to receive the second strap 3120. The second strap 3120 is received within the end loop 3130 and folded back, providing a fastening arrangement for removably securing the free end of the second strap 3120. The second strap 3120 includes a break-through end or gripping tab 3140. In at least one embodiment, the second strap 3120 includes an inner surface 3122 and an outer surface 3124, each having a different visual or tactile configuration. When the second strap 3120 is folded back and secured, the inner surface 3122 of the portion of the strap that is fed through the end loop 3130 of the second strap 3120 is exposed. This provides visual and / or tactile indication of the adjusted length.

[0407] Figure 30 A headband 5200 is shown, which has a breathable, moisture-wicking material 5240 on the vertical straps 5210 and the neck strap 5220. The breathable, moisture-wicking material 5240 can be a sports and performance knitted fabric that improves the breathability of the headband 5200 at the points of contact with the user's skin or hair. The breathable, moisture-wicking material 5240 also gives the headband 5200 an aggressive and sporty look.

[0408] Figure 31A headband 5300 is shown, having a lower strap 5310 and a middle strap 5320 in the form of a closed loop structure formed from a continuous outer shell. The continuous lower strap 5310 and middle strap 5320 form a substantial portion of the periauricular ring 5370. The continuous lower strap 5310 and middle strap 5320 are connected by a breakthrough connector 5330 in front of the ear, which forms the remaining portion of the periauricular ring 5370 in front of the ear. A vertical strap 5340 is formed at the apex 5322 of the middle strap 5320, and it is formed from exposed plastic via a breakthrough injection process. Similarly, a neck strap 5350 may also be formed from exposed plastic. Alternatively, the vertical strap 5340 and neck strap 5350 may comprise internally molded straps with a textile outer shell. The vertical straps 5340 and neck straps 5350 may also be chamfered at their connection points with the lower straps 5310 and the middle straps 5320 to improve the connection strength with the lower straps 5310 and the middle straps 5320.

[0409] Figure 32 A headband 5400 is shown, having a bottom lower strap 5410, a middle strap 5420, and a front vertical strap 5430 in the form of a closed loop structure formed by continuous outer shells. The rear vertical strap 5440 and the top lower strap 5450 are also continuous straps and can form a closed loop structure. A mesh portion 5460 extends between the front vertical strap 5430 and the rear vertical strap 5440, and between the top lower strap 5450 and the bottom lower strap 5410. The mesh portion 5460 also extends between the front portion 5412 of the bottom lower strap 5410 and the middle strap 5420. The mesh portion 5460 also forms a periauricular ring around the ear. That is, the mesh portion 5460 has a hole in which the ear can be positioned.

[0410] Figure 33 and Figure 34 Two examples of a headband 5500 are shown, which has a lower strap 5510 and a middle strap 5520 in the form of a closed loop structure formed by a continuous outer shell. The upper portion 5574 of an ear loop 5570 is defined by the middle strap 5520. The lower portion 5572 of the ear loop 5570 is defined by the lower strap 5510. A fiber mesh portion 5540 extends between the rear portion 5512 of the continuous lower strap 5510 and the rear portion 5522 of the continuous middle strap 5520, and defines the rear portion 5578 of the ear loop 5570. A continuous vertical strap 5530 extends from the lower strap 5510 at a portion in front of the ear and forms the front portion 5576 of the ear loop 5570. The middle strap 5520 covers the vertical strap 5530. The central strap 5520 is connected to the vertical strap 5530 via a breakthrough connection or arc welding. Figure 34A vertical strap 5530 with a shell is shown, which is formed of a different material than the material used to form the intermediate strap 5520 and the lower strap 5510.

[0411] Figure 35 A headband 5700 is shown, having a lower strap 5710 and a middle strap 5720 with a continuous outer shell. The lower strap 5710 extends below the user's ear, then extends vertically upward, behind the user's ear, and forward above the user's ear to form part of an ear loop 5770. A continuous vertical strap 5730 extends from the lower strap 5710 at a portion in front of the ear, forming the remainder of the ear loop 5770. The middle strap 5720 is connected to the vertical strap 5730 via a breakaway connector. The lower rear portion 5712 of the lower strap 5710 is connected by a rear panel 5740.

[0412] Figure 36 A headband 5800 is shown, having a lower strap 5810 and a middle strap 5820 in the form of a closed loop structure formed by a continuous outer shell. The continuous lower strap 5810 and middle strap 5820 extend below the user's ear, then vertically upward and around the user's ear to form a bottom portion 5872, a rear portion 5874, and a top portion 5876 of a periauricular ring 5870, and then continue forward from a position in front of the user's ear to form a portion of the middle strap 5820. A continuous vertical strap 5830 extends from the lower strap 5810 at a portion in front of the ear, forming a front portion 5878 of the periauricular ring 5870. The middle strap 5820 overlaps the vertical strap 5830 at a portion substantially parallel to it and is connected to the vertical strap 5830 by a breakthrough connection. The lower rear portion 5812 of the lower strap 5810 is connected by the rear panel or the fiber mesh portion 5840.

[0413] Figure 37 and Figure 38Two examples of a headband 5900 are shown, which has a lower strap 5910 and a middle strap 5920 formed by a continuous outer shell. A vertical strap 5930 extends from the lower strap 5910 at a portion in front of the ear and forms the front portion 5972 and top portion 5974 of a periauricular loop 5970. The vertical strap 5930 extends rearward and connects to the lower strap 5910 at a location behind the user's ear. In some configurations, the vertical strap 5930 extends around the back of the user's head. The lower strap 5910 forms the bottom portion 5976 of the periauricular loop 5970. The middle strap 5920 connects to the vertical strap 5930 at a location in front of the user's ear. A neck strap 5940 is attached to both the vertical strap 5930 and the lower strap 5910 and extends along the length of the vertical strap 5930 at the back of the user's head. Figure 37 In this design, the neck strap 5940 is made of a breathable, moisture-wicking material, which can be a sports and performance knitted fabric. The vertical strap 5930 can be covered with a textile material or have an exposed plastic core.

[0414] Figure 39 An embodiment of a headband 6100 is shown, having a lower strap 6110 and a middle strap 6120 formed from a continuous outer shell. The lower strap 6110 and the middle strap 6120 converge at a location behind the user's ear. A break-in connector 6140 connects the lower strap 6110 and the middle strap 6120 at a location in front of the user's ear. A vertical strap 6130 is formed from a break-in connector above the user's ear, starting from the apex 6122 of the middle strap 6120. The vertical strap 6130 may be covered with a textile material or an exposed plastic core.

[0415] Figure 40 One embodiment of a headband 6200 is shown, which has a lower strap 6210, a middle strap 6220, and a vertical strap 6230 formed from a continuous outer shell. In some non-limiting configurations, the continuous straps can be formed by completely knitting a continuous outer shell or by linking multiple layers of textile material together.

[0416] Figure 41An embodiment of a headband 6300 is shown, having a lower strap 6310, a middle strap 6320, and a vertical strap 6330 formed from a continuous outer shell. The continuous straps are connected to the rear strap 6340 at two points: a connection to one end of the lower strap 6310 behind the user's ear; and a connection to the vertical strap 6330 at a location above the user's ear. A mesh portion 6350 connects the lower strap 6310 and the middle strap 6320 at a location in front of the user's ear. Alternatively, the continuous straps may connect the lower strap 6310 and the middle strap 6320 at a location in front of the user's ear. A neck strap 6360 is attached to both the rear strap 6340 and the lower strap 6310 and extends along the length of a portion of the rear strap 6340 located behind the user's head. The neck strap 6360 is made of a breathable, moisture-wicking material, which can be a sports and performance knitted fabric.

[0417] Figure 42 An embodiment of the headband 6400 is shown, having a lower strap 6410 and a middle strap 6420 formed from a continuous outer shell. In some configurations, the continuous straps form a closed loop structure. The lower strap 6410 and the middle strap 6420 intersect at a location behind the user's ear. A breathable, moisture-wicking material may be positioned within an opening 6450 between the lower strap 6410 and the middle strap 6420. The lower strap 6410 and the middle strap 6420 are connected at a location in front of the user's ear by an internally molded fiber mesh portion or a strap 6440. A vertical strap 6430 is formed from a breakout joint above the user's ear, starting from the apex 6422 of the middle strap 6420. In some configurations, the vertical strap 6430 is covered by the middle strap 6420 and extends toward the lower strap 6410 to connect the lower strap 6410 and the middle strap 6420.

[0418] Figures 43A to 43BA perspective view of one embodiment of a headband 6510 that can be used with a patient interface 6500 is shown. The headband 6510 includes a central strap 6512, a lower strap 6511, and a vertical member 6513. The lower strap 6511 extends from the patient interface 6500 below the user's ear, then extends vertically upwards, behind the user's ear, and forwards above the user's ear to form part of a periauricular loop 6517. The central strap 6512 extends from a connector above the user's ear to form the upper portion of the periauricular loop 6517, thus meeting the lower strap 6511 at a connection point. The central strap 6512 extends from a connection point above the user's head. The vertical member 6513 extends from a portion in front of the ear where it connects with the lower strap 6511 to a portion in front of the ear where it connects with the central strap 6512, thus forming the remainder of the periauricular loop 6517. The middle strap 6512 may include an adjustment mechanism for adjusting the fit of the headband 6510 on the user's head. The lower strap 6511 may include an adjustment mechanism. The rear portion 6515 may include an adjustment mechanism. This adjustment mechanism allows for adjustment of the length of the straps so that the headband 6510 can fit a range of head sizes.

[0419] The lower strap 6511 and the middle strap 6512 are manufactured using an internal molding process that includes a shell, which can be knitted from a soft-textured material, making the middle strap 6512 and the lower strap 6511 feel comfortable in contact with the user's skin. Similarly, the shell can have a certain thickness and number of layers, making the headband 6510 feel comfortable in contact with the user's skin. The interior of the shell includes a plastic material to provide rigidity for the headband 6510. The middle strap 6512 and the lower strap 6511 are integrally formed at the headband connection 6514 using a breakthrough internal molding technique. The vertical member 6513 is integrally formed with the middle strap 6512 and the lower strap 6511 at each of its connections using the same breakthrough internal molding technique.

[0420] In the illustrated embodiment, the intermediate strap 6512 and the lower strap 6511 are continuous straps with a continuous outer shell. In other words, the outer shell of these straps is uninterrupted prior to the internal molding and / or breakthrough process. It should be noted that the continuous outer shell or strap may include pre-formed openings that allow the injected material to be exposed.

[0421] The rear portion 6515 of the headband 6510 wraps around the back of the user's head. It may be formed from a plastic fiber mesh manufactured in a breakthrough process. Alternatively, the rear portion 6515 may be formed from an elastic material, allowing the headband 6510 to be configured to conform to a variety of user head contours. Suitable materials may include Breath-o-prene, spacer fabric, or other stretchable and pliable fabrics. This fabric may be attached to the headband 6510 using stitching, radio frequency welding, ultrasonic welding, adhesive bonding, or any other suitable fastening mechanism.

[0422] For simplicity, the following embodiments will focus on describing additional features introduced in the corresponding figures. Therefore, features or configurations previously described may not be included every time.

[0423] Figures 44A to 44B A perspective view of one embodiment of a headband 6520 that can be used with a patient interface 6500 is shown. The headband 6520 includes a lower strap 6521, a middle strap 6522, and an upper, vertical, or top strap 6523. The lower strap 6521 extends from the patient interface 6500, passes below the user's ear, wraps around the back of the user's head, passes below the user's other ear, and finally reaches the patient interface 6500. The middle strap 6522 extends from the patient interface 6500, passes above the user's ear, wraps around the back of the user's head, passes above the user's other ear, and finally reaches the patient interface 6500. The vertical strap 6523 extends from a connection on the lower strap 6521 at a point in front of the user's ear to a connection with the middle strap 6522, then extends across the top of the user's head to another connection with the middle strap 6522, and finally reaches a point in front of the lower strap 6521 in front of the user's other ear. All the connections shown in the configuration can be formed using breakthrough internal molding.

[0424] The headband 6520 includes a rear fiber mesh portion 6525 located at the rear of the user's head. The rear fiber mesh portion 6525 may be formed by breakthrough internal molding. The fiber mesh portion 6525 may be integrally formed with the headband 6520. Alternatively, the fiber mesh portion 6525 may be made of a more flexible material (e.g., Breath-o-prene) and attached to the lower strap 6521 and the middle strap 6522 by any suitable means (stitching, radio frequency welding, adhesive, etc.).

[0425] Figures 45A to 45BA perspective view of one embodiment of a headband 6530 that can be used with a patient interface 6500 is shown. The headband 6530 includes a rear mesh portion 6535 that includes holes or gaps. These holes are used to increase the flexibility and breathability of the rear portion 6535. The mesh portion 6535 can be an internally molded plastic formed by a breakthrough process, or it can be an elastic fabric (e.g., Breath-o-prene, spacer fabric, etc.).

[0426] Figures 46A to 46C A perspective view of one embodiment of a headband 6540 that can be used with a patient interface 6500 is shown. The headband 6540 includes a lower strap 6541 and a middle strap 6542 in the form of a closed loop structure formed by a continuous outer shell. The lower strap 6541 and the middle strap 6542 form part of a periauricular loop. A vertical member 6544 extends from a connection point with the lower strap 6541 at a location in front of the ear to a connection point with a top strap 6543 at a location in front of the ear, thereby forming the remainder of the periauricular loop. The top strap 6543 crosses between the upper portions of the right and left periauricular loops. A rear strap 6545 crosses between the rear portions of the right and left periauricular loops. In at least one embodiment, at least one of the top strap 6543 and the rear strap 6545 may be made of a flexible material (e.g., Breath-o-prene) and attached to the lower strap 6541 and the middle strap 6542 by any suitable means (stitching, radio frequency welding, adhesive, etc.). In at least one embodiment, either the top strap 6543 or the rear strap 6545 may be manufactured using a breakthrough in-moldering process. In at least one embodiment, both the top strap 6543 and the rear strap 6545 may be manufactured using a breakthrough in-moldering process. The rear strap 6545 may include an adjustment mechanism.

[0427] Figures 47A to 47BA perspective view of one embodiment of a headband 6550 that can be used with a patient interface 6500 is shown. The headband 6550 includes a lower strap 6551 and a middle strap 6552 in the form of a closed loop structure formed from a continuous shell. The lower strap 6551 and the middle strap 6552 form part of an ear loop. A top strap 6553 is formed by a breakthrough internal molding process and extends from a connection on the upper portion of the right ear loop to a connection on the upper portion of the left ear loop. A first portion 6555 of the rear strap is formed of a soft quilted fabric or material. A second portion 6557 of the rear strap of the headband 6550 is formed of a rear fibrous mesh portion extending between the lower rear portion of the right ear loop and the lower rear portion of the left ear loop. The second portion 6557 of the rear strap can be made of a soft quilted fabric or material, or it can be made of a plastic material using an internal molding process.

[0428] Figures 48A to 48B A perspective view of one embodiment of a headband 6560 that can be used with a patient interface 6500 is shown. The headband 6560 includes a first lower strap 6564, which is formed of a continuous shell. The first lower strap 6564 extends laterally below the user's right ear, wraps around the back of the user's head, and meets a middle strap 6562 at a connection on the opposite side of the user's head. The connection where the first lower strap 6564 and the middle strap 6562 meet is generally located above the user's left ear. The headband 6560 includes a second lower strap 6566, which is a segmented strap comprising two shell lengths. The second lower strap 6566 extends laterally below the user's left ear, wraps around the back of the user's head, and then intersects with the first lower strap 6564 at a rear connection. The second lower strap 6566 extends from the rear connection to the connection where it meets the middle strap 6562, which is typically located above the user's right ear. The cores of both the first lower strap 6564 and the second lower strap 6566 are integrally formed using a breakthrough internal molding process.

[0429] The central strap 6562 extends from the patient interface 6500 above the user's right ear, where it meets the second lower strap 6566 at a connecting point. The central strap 6562 continues to extend from the connecting point above the user's head, where it meets the first lower strap 6564 at another connecting point. The central strap 6562 continues to extend into the patient interface 6500.

[0430] Figures 49A to 49BA perspective view of one embodiment of a headband 6570 that can be used with the patient interface 6500 is shown. A middle strap 6572 extends from the patient interface 6500, passes above the user's ear, wraps around the back of the user's head, passes above the user's other ear, and finally reaches the opposite side of the patient interface 6500. A top strap 6573 may be formed from a breakaway joint having the middle strap 6572. A lower strap 6571 extends from the patient interface 6500, passes below the user's ear, wraps around the back of the user's head, passes below the user's other ear, and finally reaches the opposite side of the patient interface 6500.

[0431] The headband 6570 includes an ear loop 6577. The ear loop 6577 extends from the back of the user, passes above the front of the user's right ear, and extends around the front of the right ear. It extends below the user's right ear and continues to extend around the back of the user's head. It extends below the front of the user's left ear and extends around the front of the left ear, continues above and behind the user's left ear, and then meets itself at the back of the user's head.

[0432] The periauricular loop 6577 includes a rear fiber mesh portion 6575 located at the back of the user's head, spanning between the opposite ends of the periauricular loop 6577. The rear fiber mesh portion 6575 may be formed by breakthrough internal molding. The fiber mesh portion 6575 may be integrally formed with the headband 6570. Alternatively, the fiber mesh portion 6575 may be made of a more flexible material (e.g., Breath-o-prene) and attached to the lower strap 6571 and the middle strap 6572 by any suitable means (stitching, radio frequency welding, adhesive, etc.). The periauricular loop 6577 is connected to the middle strap 6572 and the lower strap 6571 of the headband 6570 by means of stitching, radio frequency welding, ultrasonic welding, or adhesive bonding.

[0433] Figures 50A to 50BA perspective view of one embodiment of a headband 6580 that can be used with a patient interface 6500 is shown. The headband 6580 includes a lower strap 6581 that extends from the patient interface 6500 below the user's ear. A middle strap 6582 extends from the patient interface 6500 above the user's ear. The middle strap 6582 and the lower strap 6581 converge at the back of the user's head to form a rear strap 6585. The middle strap 6582 and the lower strap 6581 form a first portion 6587 of a periauricular ring. A top strap 6583 is formed by a breakthrough joint above the user's ear. A second portion 6589 of the periauricular ring is formed by a breakthrough fiber mesh portion. In at least one embodiment, the second portion 6589 of the periauricular ring and the top strap 6583 can be integrally formed using a breakthrough process and attached to the first portion 6587 of the periauricular ring using a suitable method (stitching, etc.).

[0434] Figures 51A to 51B A non-limiting exemplary embodiment of a headband 6590 for use with a patient interface 6500 is shown. The headband 6590 includes a lower strap 6591 and a middle strap 6592 in the form of a closed loop structure formed from a continuous outer shell. The lower strap 6591 and the middle strap 6592 form part of a periauricular ring. A top strap 6593 is formed by a breakthrough internal molding process. The top strap 6593 includes a first portion 6594 and a second portion 6595, the first portion extending from a chamfered connection on the upper portion of the right periauricular ring toward the top of the user's head, and the second portion also extending from a chamfered connection on the upper portion of the left periauricular ring toward the top of the user's head.

[0435] The first portion 6594 and the second portion 6595 of the top strap 6593 engage to allow the length of the top strap 6593 to be adjusted by the user of the patient interface 6500. The first portion 6594 and the second portion 6595 of the top strap 6593 can engage with each other by including a push-in adjustment mechanism. Figure 51B As shown, the push-fit adjustment mechanism may include one or more protrusions 6599 on the second portion 6595 of the top strap 6593, and one or more mating recesses 6598 on the first portion 6594 of the top strap 6593. The protrusions 6599 of the second portion 6595 can be pushed into or pressed into the recesses 6598 on the first portion 6594 to fix the length of the top strap 6593 as needed. The protrusions 6599 may be formed by a breakthrough internal molding process. Any other suitable adjustment mechanism may be used to connect the first portion 6594 and the second portion 6595 to set the length of the top strap 6593.

[0436] The rear strap 6597 is formed by a breakthrough in-mold process and extends from a chamfered connection on the rear portion of the right ear loop to a chamfered connection on the rear portion of the left ear loop. In the illustrated configuration, the rear strap 6597 includes a housing surrounding a plastic core that spans the length of the strap. In at least one configuration, the rear strap 6597 may include a plastic structure spanning the rear of the headband 6590. In at least one embodiment, the rear strap 6597 may include a length adjustment mechanism.

[0437] Figures 52A to 52C A perspective view of one embodiment of a headband 6610 that can be used with a patient interface 6600 is shown. The headband 6610 includes a middle strap 6611 and a rear strap 6613, both formed from a continuous housing 6601. A top strap 6612 is formed by a breakthrough internal molding process. The top strap 6612 extends from a connection 6617 on the upper portion of the middle strap 6611 and / or the rear strap 6613, and extends over the user's head to a connection 6617 on the upper portion of the middle strap 6611 and / or the rear strap 6613 on the opposite side of the user's head. In at least one embodiment, the top strap 6612 may be formed from a chamfered connection.

[0438] The adjacent portions of the connecting portion 6617, the middle strap 6611, and the rear strap 6613 include a support structure 6615. Figure 52B A cross-sectional view of the connecting portion 6617 and adjacent portions along lines 52B-52B is shown, illustrating the support structure 6615. In contrast, Figure 52C A cross-sectional view of the rear strap 6613 along line 52C-52C, without the support structure 6615, is shown. The support structure 6615 may be arc-shaped, following the contours of the middle strap 6611, the rear strap 6613, and the connecting portion 6617. The support structure 6615 can extend from a first position in front of the user's ear to a second position behind the user's ear. In the illustrated configuration, the support structure 6615 is formed of a plastic or polymer material 6602. The support structure 6615 may be formed by a breakthrough internal molding process. The support structure 6615 may be overmolded onto the headband 6610. The support structure 6615 can provide a structure to help the headband 6610 maintain its shape and / or contribute to the structural integrity of the headband 6610.

[0439] Figures 53A to 53BA perspective view of one embodiment of a headband 6620 that can be used with a patient interface 6600 is shown. The headband 6620 includes a lower strap 6621 and a middle strap 6622 in the form of a closed loop structure formed from a continuous outer shell. The lower strap 6621 and the middle strap 6622 form part of a periauricular ring. The headband 6620 includes a first rear portion 6624 and a second rear portion 6625. The second rear portion 6625, the lower strap 6621, and the middle strap 6622 are integrally formed by a breakthrough internal molding process. The lower strap 6621 and the middle strap 6622 include a textile outer shell 6601 having an internally molded plastic core 6602. The second rear portion 6625 includes a textile outer shell 6601 having an internally molded plastic core 6602. The fiber web portion 6628, formed by a breakthrough internal molding process, extends between the lower binding strap 6621 and the middle binding strap 6622 and the second rear portion 6625.

[0440] The fiber web portion 6628 forms the plastic core of the first rear portion 6624. For example... Figure 53B As shown, the first rear portion 6624 includes a molding overlay material 6603 on at least one side of the fiber web. In the illustrated configuration, the first rear portion 6624 includes a soft-to-the-touch molding overlay material 6603 on both its outer and inner surfaces. This molding overlay material 6603 can enhance the comfort experienced by the user of the headband 6620. The first rear portion 6624 and the second rear portion 6625 are configured to form a top strap 6623 across the top of the user's head and a rear strap 6627 across the back of the user's head.

[0441] Figures 54A to 54C A headband 6630 is shown, having a lower strap 6631 and a middle strap 6632 formed by a continuous outer shell. An upper portion of a partial periauricular ring is defined by the middle strap 6632. A lower portion of the partial periauricular ring is defined by the lower strap 6631. A fiber mesh portion 6637 extends between a rear portion of the continuous middle strap 6632 and a rear portion of the continuous lower strap 6631, and defines the rear portion of the partial periauricular ring. Figure 54B This is a close-up view of the fiber web portion 6637. The fiber web portion 6637 can be formed by a breakthrough internal molding process. Figure 54C The fiber web portion 6637 is shown along... Figure 54B A cross-sectional view of lines 54C-54C. The fiber web portion 6637 includes a covering molding material 6603. In at least one embodiment, the covering molding material 6603 may be a soft-to-the-touch material.

[0442] The top strap 6633 is formed by a breakthrough internal molding process. The top strap 6633 extends from a connection on the upper portion of the middle strap 6632 and / or the rear strap 6635, and extends over the user's head to a connection on the upper portion of the middle strap 6632 and / or the rear strap 6635 on the opposite side of the user's head. In at least one embodiment, the top strap 6633 may include a chamfered connection. The top strap 6633 may include a soft-touch overmolded material at least on its upper surface, lower surface, or both surfaces.

[0443] Figures 55A to 55C A headband 6640 is shown, comprising a continuous lower strap 6641 and a combined continuous middle vertical strap 6642. The headband 6640 further includes a combined upper rear strap 6643. A mesh portion 6645 extends between a first vertical strap and a second vertical strap. The mesh portion 6645 also extends between a first rear strap and a second rear strap. Figure 55B The fiber web portion 6645 is shown along... Figure 55A The cross-section of line 55B-55B in the diagram. Figure 55C A close-up view of the web portion 6645 is shown. In at least one embodiment, the web portion 6645 may be formed by a breakthrough internal molding process. In at least one embodiment, the strap may include a knitted tube housing 6601.

[0444] Figures 56A to 56B A headband 6650 is shown, having a lower strap 6651 and a middle strap 6652 in the form of a closed loop structure formed by a continuous outer shell. The continuous middle strap 6652 and lower strap 6651 form a substantial portion of the periauricular ring. A top strap 6653 extends from a connection 6655 on the upper right side of the partial periauricular ring to a connection on the upper left side of the partial periauricular ring. Similarly, a rear strap 6657 extends from a connection on the rear right side of the partial periauricular ring to a connection on the rear left side of the partial periauricular ring.

[0445] like Figure 56B As shown, the top strap 6653 and the rear strap 6657 may be chamfered or tapered at their connections with the middle strap 6652 and the lower strap 6651 to improve the connection strength with the middle strap 6652 and the lower strap 6651. In at least one embodiment, the top strap 6653 may be formed of exposed plastic. In at least one embodiment, the top strap 6653 may consist of an internally molded strap with a textile outer shell. In at least one embodiment, the rear strap 6657 may be formed of exposed plastic. In at least one embodiment, the rear strap 6657 may consist of an internally molded strap with a textile outer shell.

[0446] Figures 57A to 57C A perspective view of one embodiment of a headband 6660 that can be used with a patient interface 6600 is shown. The headband 6660 has a central strap 6662 formed of a continuous outer shell. The headband 6660 has a lower strap 6661 formed of a continuous outer shell. The central strap 6662 extends from the mask assembly above the user's ear and continues to extend across the back of the user's head. The upper portion of the periauricular loop is defined by the central strap 6662. The lower strap 6661 extends from the mask assembly below the user's ear and continues to extend across the back of the user's head. The lower portion of the periauricular loop is defined by the lower strap 6661.

[0447] The headband 6660 includes a first vertical member 6665 and a second vertical member 6666. The first vertical member 6665 spans the distance between the lower strap 6661 and the middle strap 6662 in front of the user's ear, thus forming the front portion of a periauricular ring. The first vertical member 6665 can be formed by a breakthrough in-mold molding technique. The first vertical member 6665 can be exposed plastic. Figure 57B As shown, the second vertical member 6666 spans the distance between the lower strap 6661 and the middle strap 6662 behind the user's ear, thus forming the rear portion of the periauricular ring. The second vertical member 6666 can be formed by a breakthrough in-mold molding technique. The second vertical member 6666 can be exposed plastic 6602. Figure 57C It is the second vertical member 6666 along Figure 57B Cross-sectional view of line 57C-57C in the diagram.

[0448] The top strap 6663 extends from the connecting portion 6668 on the upper portion of the middle strap 6662 and / or the rear strap 6669, and extends over the user's head to the connecting portion 6668 on the upper portion of the middle strap 6662 and / or the rear strap 6669 on the opposite side of the user's head. The top strap 6663 may be formed by a breakthrough in-mold molding process. The top strap 6663 may include exposed plastic.

[0449] Figures 58A to 58BA perspective view of one embodiment of a headband 6670 that can be used with a patient interface 6600 is shown. The headband 6670 has a central strap 6672 formed of a continuous outer shell. The headband 6670 has a lower strap 6671 formed of a continuous outer shell. The central strap 6672 extends from the face mask assembly above the user's ear and continues to extend across the back of the user's head. The upper portion of a partial periauricular loop is defined by the central strap 6672. The lower strap 6671 extends from the face mask assembly below the user's ear and continues to extend across the back of the user's head. The lower portion of a partial periauricular loop is defined by the lower strap 6671.

[0450] The fiber mesh portion 6677 extends between the rear portion of the continuous middle binding 6672 and the rear portion of the continuous lower binding 6671, and defines the rear portion of the periauricular ring. The fiber mesh portion 6677 can be formed by a breakthrough internal molding process.

[0451] The top strap 6673 is formed by a breakthrough internal molding process. The top strap 6673 extends from a connection on the upper portion of the middle strap 6672 and / or the rear strap 6678, and extends over the user's head to a connection on the upper portion of the middle strap 6672 and / or the rear strap 6678 on the opposite side of the user's head. In at least one embodiment, the top strap 6673 may include a chamfered connection 6675. The top strap 6673 may be exposed plastic, may include a fabric shell, or may include at least one overmolding material.

[0452] Figures 59A to 59C A headband 6680 is shown, comprising a continuous lower strap 6681 and a combined continuous middle vertical strap 6682. The headband 6680 further includes a combined upper rear strap 6683. A mesh portion 6685 extends around the back portion of the user's ear. The mesh portion 6685 may be formed by a breakthrough internal molding process.

[0453] The lengths of the continuous central vertical strap 6682 and the continuous upper rear strap 6683 are connected via an invisible joint, as shown below. Figure 59BAs shown. Along this joint, the plastic core of a continuous central vertical strap 6682 is integrally formed with the plastic core 6602 of a continuous upper rear strap 6683. In at least one embodiment, the continuous central vertical strap 6682 and the continuous upper rear strap 6683 may include a common textile shell 6601. In at least one embodiment, the continuous central vertical strap 6682 and the continuous upper rear strap 6683 are formed from two separate textile shells including at least one adjacent surface. Furthermore, the lengths of the continuous upper rear strap 6683 and the lower strap 6681 are connected via an invisible joint.

[0454] Figures 60A to 60B A perspective view of one embodiment of a headband 6690 that can be used with a patient interface 6600 is shown. The headband 6690 includes a lower strap 6691 and a middle strap 6692 in the form of a closed loop structure formed from a continuous outer shell. The continuous middle strap 6692 and lower strap 6691 form a substantial portion of the periauricular ring. A top strap 6693 extends from a connection 6695 on the upper portion of the right periauricular ring to a connection 6696 on the upper portion of the left periauricular ring. The top strap 6693 may be formed by a breakthrough internal molding process. In at least one embodiment, the top strap 6693 may consist of an internally molded strap having a textile outer shell.

[0455] The headband 6690 includes a back strap 6697. The back strap 6697 extends from a connection on the rear portion of the right periauricular ring to a connection on the rear portion of the left periauricular ring. The back strap 6697 can be formed by an internal molding process using a plastic core and a fabric or textile shell. The back strap 6697 can have a molded texture embossed onto the strap 6697, or can include a contour defined during the molding process. Figure 60A The strap 6697 is shown, which has multiple hexagonal holes arranged in rows along the length of the strap 6697. Figure 60B This is a close-up view of rows of hexagonal holes arranged along the length of the rear strap 6697. These holes protrude through the thickness of the strap 6697. This profile allows for a degree of stretch or elasticity in the plastic core. This flexibility allows the headband 6690 to move over the patient's head or improves the patient's perception of the headband 6690. Additionally, the textured finish of the strap 6697 improves the aesthetic appearance and tactile appeal of the headband 6690. That is, the strap 6697 can appear less rigid and more comfortable. The holes improve the breathability of the strap 6697, thereby improving user comfort.

[0456] Alternatively, the rear strap 6697 may include a plurality of hexagonal indentations arranged in rows along the length of the strap 6697. It should be understood that the indentations are not limited to a hexagonal shape, but may include a variety of shapes, sizes, positions on the strap, geometries, combinations of shapes, etc. In at least one configuration, the honeycomb patterned plastic core does not extend to the edge of the outer shell of the strap 6697. This provides a soft edge to improve user comfort. In at least one embodiment, the rear strap 6697 may be exposed plastic.

[0457] Figures 61A to 61C A perspective view of one embodiment of a headband 7110 that can be used with a patient interface is shown. The headband 7110 includes a lower strap 7111, a middle strap 7112, and a vertical or top strap 7113. The lower strap 7111 is a continuous strap with a continuous outer shell. The middle strap 7112 is a continuous strap with a continuous outer shell. The vertical strap 7113 is a segmented strap. In other words, the vertical strap 7113 is formed of multiple outer shells or segmented outer shells.

[0458] In at least one embodiment, the vertical strap 7113 may be a continuous strap with a continuous outer shell. When the vertical strap 7113 extends above the user's head, it may pass under the central strap 7112. When the vertical strap 7113 extends above the user's head, it may pass over the central strap 7112. The vertical strap 7113 can be adhesively attached to the central strap 7112, can be attached via a suitable connecting mechanism (such as a hook-and-loop connection system), or can be independent of the central strap 7112.

[0459] The middle strap 7112 and the lower strap 7111 include an invisible joint spanning the rear section of each strap, such as... Figure 61B As shown. Along this invisible joint, the middle strap 7112 and the lower strap 7111 may include a common plastic core 7002. Figure 61C It shows Figure 61B Cross-sectional view along line 61C-61C. The middle strap 7112 and the lower strap 7111 may have separate textile or fabric shells 7001, which are configured such that the common plastic core 7002 of these straps is not visible.

[0460] Figures 62A to 62BA perspective view of one embodiment of a headband 7120 that can be used with a patient interface 7100 is shown. The headband 7120 has a central strap 7122 formed of a continuous outer shell. The headband 7120 has a lower strap 7121 formed of a continuous outer shell. The central strap 7122 extends from the face mask assembly above the user's ear and continues to extend across the back of the user's head. The upper portion of the periauricular loop is defined by the central strap 7122. The lower strap 7121 extends from the face mask assembly below the user's ear and continues to extend across the back of the user's head. The lower portion of the periauricular loop is defined by the lower strap 7121.

[0461] The top strap 7123 extends from the connection portion on the upper portion of the middle strap 7122 and / or the rear strap 7128, and extends over the user's head to the connection portion on the upper portion of the middle strap 7122 and / or the rear strap 7128 on the opposite side of the user's head. The top strap 7123 is formed by a breakthrough internal molding process. The top strap 7123 may include a chamfered connection portion. The top strap 7123 may be exposed plastic, may include a fabric shell, or may include at least one overmolding material.

[0462] The headband 7120 includes a vertical member 7125. The vertical member 7125 spans the distance between the lower strap 7121 and the middle strap 7122 in front of the user's ear, thus forming part of a periauricular ring. The vertical member 7125 is formed of a soft-to-the-touch material (such as fabric or foam). In the illustrated configuration, the vertical member 7125 includes multiple holes. These multiple holes can improve the elasticity and / or flexibility of the vertical member 7125, thereby enhancing the user's perceived comfort.

[0463] The fiber mesh portion 7127 extends between the rear portion of the continuous middle strap 7122 and the rear portion of the continuous lower strap 7121, and defines the rear portion of the periauricular ring. The fiber mesh portion 7127 may be made of a soft-to-the-touch material (such as fabric or foam). In the illustrated configuration, the fiber mesh portion 7127 includes multiple holes. The multiple holes can improve the elasticity and / or flexibility of the fiber mesh portion 7127, thereby enhancing the user's perceived comfort.

[0464] In at least one embodiment, the vertical member 7125 may be formed of quilted fabric. In at least one embodiment, the vertical member 7125 may be formed by a breakthrough internal molding process to include multiple holes. In at least one embodiment, the vertical member 7125 may include multiple indentations instead of multiple holes. In at least one embodiment, the fiber web portion 7127 may be formed of quilted fabric 7129, such as... Figure 62BAs shown. In at least one embodiment, the web portion 7127 may be formed by a breakthrough internal molding process to include multiple holes. In at least one embodiment, the web portion 7127 may include multiple indentations instead of multiple holes.

[0465] Figures 63A to 63B An embodiment of a headband 7130 is shown, the headband having a provided quilted fabric or material 7132 attached to the portion of the headband 7130 that comes into direct contact with the user's skin or hair (e.g., on the back of the user's neck). The quilted material 7132 is not only soft in texture but also provides cushioning, which improves the comfort of the headband 7130, making the user want to wear it while lying in bed. The quilted material 7132 can be sewn or welded to the internal molded straps or fiber mesh portion of the headband 7130. The various configurations disclosed are not limited to quilted materials (…). Figure 63B (as shown), but may include fabrics and textiles with a variety of material properties (such as, but not limited to, soft, padded, breathable, moisture-wicking, and tight / sticky textures). Figure 63C (as shown in the image).

[0466] Figures 64A to 64B An embodiment of a headband 7140 is shown, the headband having multiple portions provided to be attached to the headband 7140 and in direct contact with the user's skin or hair, made of a fabric or textile material. The headband 7140 includes a vertical member 7142 and a rear strap 7144, which are formed of a material used to provide cushioning and improve the comfort of the headband 7140. This material may be sewn or welded to an internal molded strap of the headband 7140. The various configurations disclosed are not limited to fabric or textile materials, but may include quilted materials (…). Figure 64B (As shown in the image). These materials can have a variety of material properties, such as, but not limited to, softness, padding, breathability, moisture absorption, and a firm / sticky texture.

[0467] Figure 65 An embodiment of a trademark gripper 3300 that can be used with one embodiment of the disclosed headband is shown. The trademark gripper 3300 can be formed from plastic using a breakthrough in-mold molding process.

[0468] Internally molded strap connector

[0469] Figures 66A to 73Various views are shown of a connector 3400 positioned above the joint between two straps in an internally molded headband embodiment. The connector 3400 is used at the joint or connection 3500 between two or more adjacent straps in an internally molded headband. More specifically, the connector 3400 is used to join two or more straps together using breakthrough internal molding. The connector 3400 can be used with any type of connection 3500 between two or more straps, and the connection 3500 shown herein is merely one example. The connector 3400 provides a cleaner and stronger connection between straps and also improves the ease of aligning the straps within the molding tool.

[0470] like Figure 66A and Figure 67 As shown, the first strap 3710 and the second strap 3720 are connected at a T-shaped connection between the end of the first strap 3710 and the center or middle portion of the second strap 3720 (i.e., a portion between the ends of the second strap 3720). A connector 3400 is positioned above the first strap 3710 and the second strap 3720 at the connection 3500. That is, the connection 3500 is positioned within the connector 3400 such that the connector 3400 surrounds the connection 3500. The first strap 3710 and the second strap 3720 are connected via a breakthrough internal molding process, during which the plastic core 3800 is injected at the injection point 3600 (at... Figure 66A The plastic core material 3800 is injected into the second strap 3720 at the end shown in the diagram. The plastic core material 3800 fills and propagates through the second strap 3720. Upon reaching the connecting portion 3500, the plastic core material 3800 breaks through the sidewall of the textile shell of the second strap 3720 to fill all or part of the cavity of the textile shell of the first strap 3710, as shown in the diagram. Figure 66A The red arrow at the connection point is indicated in the diagram. In some configurations, connector 3400 has a cavity 3420 that is also filled with a plastic core 3800 that extends beyond the sidewalls of the textile outer shells of the first strap 3710 and the second strap 3720. The plastic core 3800 can also be integrated with connector 3400, such that the plastic core 3800 and connector 3400 are integrally formed. In some configurations, the plastic core 3800 and connector 3400 can be formed from the same or similar materials.

[0471] The connector 3400 accommodates any loose wires at the ends of the straps within the connector 3400, giving the connection portion 3500 a clean aesthetic appearance. That is, the loose ends of the first strap 3710 and / or the second strap 3720 are accommodated within the connector 3400, preventing further wear on the straps 3710 and 3720. Additionally, the connector 3400 may have an opaque color, thus concealing the appearance of the loose ends and giving the connection portion 3500 a cleaner aesthetic appearance. Furthermore, the connector 3400 defines the final shape of the connection portion 3500 and accommodates any protruding plastic flash from the ends of the first strap 3710 and the second strap 3720, giving the connection portion 3500 a clean aesthetic appearance.

[0472] Connector 3400 also provides an abutment edge 3417 for connecting the first strap 3710 and the second strap 3720. This abutment edge is wider than the end of the first textile strap 3710 (i.e., without the connection portion 3500 of connector 3400), providing a larger connection area between the first strap 3710 and the second strap 3720. In other words, connector 3400 provides a wider chamfered connection portion 3500 between the end of the first strap 3710 and the housing of the second strap 3720, providing a larger connection area and thus increasing the strength of the connection portion 3500. Figure 67 As shown, the end of the first strap 3710 is both filled and surrounded by plastic material, rather than having plastic material inside the tube of the strap shell. Therefore, the strength of the connection 3500 is increased.

[0473] Figures 68A to 68D Various views of connector 3400 are shown. As shown, connector 3400 includes a tubular sheath having a cavity 3420 between the end 3418 of the wrapping strap and the adjacent end 3416. Connector 3400 has a body 3410 composed of a first half 3412 and a second half 3414 connected along opposite edges. In the configuration shown, the first half 3412 and the second half 3414 are identical. In other configurations, the first half 3412 and the second half 3414 are different and / or asymmetrical. The open ends of both the first half 3412 and the second half 3414 form the adjacent end 3416 and the end 3418 of the wrapping strap of connector 3400. The end 3418 of the wrapping strap receives or surrounds the first strap 3710, and the adjacent end 3416 receives or abuts against the second strap 3720. Figure 68BAs shown, connector 3400 has a somewhat trapezoidal profile, such that one end is wider than the other. The wider end of connector 3400 forms an adjacent end 3416, while the narrower end forms an end 3418 that surrounds the strap. In some configurations, the width of the adjacent end 3416 can be twice the width of the end 3418 that surrounds the strap.

[0474] The end 3418 of the surrounding strap defines an elliptical hole configured to fit snugly against and abut against the outer surface of the textile strap housing of the first strap 3710. When viewed from below, the adjacent end 3416 forms a substantially rectangular hole with rounded ends (e.g., Figure 68A (As shown). The adjacent end 3416 is bent to match the shape and curvature of the second strap 3720. The edge of the adjacent end 3416 is configured to overhang over and surround the outer edge of the second strap 3720 (adjacent edge 3417 and...). Figure 68B The area between the dotted lines extends over the second strap 3720. The edge of the adjacent end 3416 is also configured to be positioned above the outer surface of the textile strap housing of the second strap 3720. In some configurations, the overhanging edge 3419 may form a loose fit with the textile strap housing of the second strap 3720, such that the connector 3400 does not restrict the flow of the plastic core 3800 through the second strap 3720.

[0475] During the internal molding of the first strap 3710 and the second strap 3720, the connector 3400 allows the end of the first strap 3710 to align and abut against the edge of the second strap 3720 without any gap between them. That is, the tight fit provided by the connector 3400 with the first strap 3710 maintains alignment of the first strap 3710 in the molding tool before injection molding of the plastic core 3800. Unlike the straps 3710 and 3720, the connector 3400 is semi-rigid and retains its shape, allowing it to be reliably positioned within the molding tool.

[0476] During the assembly of straps 3710, 3720 and connector 3400, connector 3400 is positioned above the tubular textile housing of the first strap 3710. That is, as Figure 69 As shown, connector 3400 slides over first strap 3710, such that the end of first strap 3710 is positioned inside connector 3400. Then, the abutment edge 3417 of connector 3400 abuts against the edge of the textile housing of second strap 3720. Figure 70As shown, the end of the first strap 3710 is positioned within the cavity 3420 of the connector 3400 adjacent to the edge of the second strap 3720. The cavity 3420 is a hollow region defined by a first half 3412, a second half 3414, an end 3418 surrounding the strap, and an adjacent end 3416. The connector 3400 fits snugly onto the first strap 3710, thus holding the connector 3400 securely attached to the first strap 3710.

[0477] The assembled straps 3710, 3720 and connector 3400 are positioned and aligned within an injection molding tool. A plastic core material 3800 is injected into an injection point 3600 at one end of the second textile strap 3720, then breaks through the sidewall of the second strap 3720 to fill the first strap 3710 (see...). Figure 66A (The arrow in the image). Therefore, as... Figure 71 and Figure 72 As shown, the cavity 3420 of connector 3400 is also filled with a plastic core 3800, which extends beyond the sidewall of the second strap 3720. The plastic core 3800 within the straps 3710 and 3720 forms an integral structure with the cavity 3420 of connector 3400. In some configurations, the plastic core 3800 is integrated with connector 3400, such that connector 3400, straps 3710 and 3720, and plastic core 3800 are formed as a single integral structure.

[0478] Those skilled in the art will understand that the connector 3400 and the strap arrangement are not limited to a T-shaped connection, but can be used to connect straps 3710, 3720 with connection portions 3500 at various angles. Similarly, the connector 3400 can be shaped and configured to connect more than two straps together. For example, the connector 3400 may have multiple ends 3418 surrounding or adjacent to the straps 3416.

[0479] In an alternative configuration, connector 3400 (which is substantially the same as in the aforementioned embodiment) is integrally formed with the first strap 3710 by covering one end of a molded tubular textile strap housing, as shown below. Figure 73 As shown. The abutting end 3416 of connector 3400 extends from the end of the textile strap, allowing it to align and abut with the second strap 3720. The cavity 3420 of connector 3400 remains hollow, allowing the plastic core material 3800 to flow through the second strap 3720 and penetrate into the first strap 3710. This configuration increases the strength of the joint between the first strap 3710 and the second strap 3720 by providing a permanent bond between the end 3418 of connector 3400 surrounding the strap and the first strap 3710.

[0480] In some embodiments, at least one of the first strap 3710 and the second strap 3720 may comprise a woven textile shell. The woven textile shell comprises multiple yarns provided in at least two different colors or shades. Weaving different colored yarns creates color patches with random or semi-random patterns within the textile shell, giving it a mottled appearance. In some cases, this mottled appearance can conceal or hide certain physical features formed by the plastic core, such as soft edges (…). Figure 2B The transition between the 222 material and the core material makes the features (and the headband) look softer.

[0481] In another alternative configuration, connector 3400 can be configured such that it does not overhang the edge of the second strap 3720. Instead, connector 3400 is configured to directly abut and abut against the edge of the second strap 3720, as... Figure 73 As shown. Therefore, connector 3400 is substantially or completely coupled to the breakthrough plastic core 3800. That is, compared to the previously described connector arrangement, the overhang portion of the previous connector arrangement was not coupled to the plastic core 3800.

[0482] Internal molded connector

[0483] Figures 74A to 78B Demonstrates the use of forming Figure 1A Various views of the internally molded straps, connecting portions, and joints of the forked headband 100 are shown. The forked headband 100 includes a top strap 140, a bottom strap 150, and a faceplate connector 180. In some configurations, the forked headband 100 is assembled by connecting the top strap 140 to the bottom strap 150. That is, each of the top strap 140 and the bottom strap 150 is formed separately via internal molding before connecting the top strap 140 to the bottom strap 150. That is, in some configurations, the top strap 140 and the bottom strap 150 are positioned within a molding tool and connected via overmolding. Once the top strap 140 and the bottom strap 150 are formed, they are connected to form the forked headband 100. However, in some configurations, the top strap 140 and the bottom strap 150 may move misaligned with each other while arranged within the molding tool and / or during the overmolding process. Figures 74A to 78B Various strap connectors are shown that keep the top strap 140 connected and aligned with the bottom strap 150 during the manufacturing and molding process.

[0484] Figure 74A The top strap 140 was shown before assembly. Figure 74BThis shows the bottom strap 150 before assembly. The top strap 140 and bottom strap 150 are formed separately by injecting a plastic core material 210 into a knitted or braided tubular shell 220 via internal molding. Figure 74A As shown, the top strap 140 comprises a substantially straight and continuous strap having a male connector portion 4002 formed at each end. The male connector portion 4002 is integrally formed with the plastic core 210 and is a single unit. The housing 220 is continuous along its entire length. The injection points of the top strap 140 may be located at one or both of its ends. That is, one or two male connectors may be the locations for injecting the plastic core 210 into the injection points in the housing 220.

[0485] The bottom strap 150 includes a plastic core 210 injected into a first braided outer shell portion 220A and a second braided outer shell portion 220B. The outer shell portions 220A and 220B can form the left and right sides of the top strap 140 and the bottom strap 150, respectively. The outer shell portions 220A and 220B have a first free end 4020 and a second free end 4022. A central injection point 4010 is positioned between the first free ends 4020, such that the outer shell portions 220A and 220B are filled from the first free ends 4020 by the plastic core 210. The plastic core 210 filling the outer shell portions 220A and 220B is integrally formed and is a single unit along its entire length. That is, the plastic core 210 connects the outer shell portions 220A and 220B to connect the outer shell portions 220A and 220B and form the bottom strap 150.

[0486] In some configurations, the housing portions 220A and 220B are partially filled with the plastic core material 210. That is, the second ends 4022 of the housing portions 220A and 220B can be hollow, such that the bottom strap 150 has a hollow free end 4030. The hollow free end 4030 of the bottom strap 150 can accommodate and receive multiple portions of the faceplate connector 180 (see...). Figure 1A That is to say, multiple parts of the mask connector 180, such as the filament core 1550 (see...). Figures 15A to 15D The faceplate connector 180 can be housed within the housing portions 220A and 220B of the hollow free end 4030. In some configurations, the housing portions 220A and 220B can be filled with a plastic core 210 by the length of the bottom strap 150. That is, the plastic core 210 can extend between the first free end 4020 and the second free end 4022 of the housing portions 220A and 220B. In some configurations, multiple portions of the faceplate connector 180 can be formed on the second free end 4022 of the bottom strap 150.

[0487] The bottom strap 150 includes a female connector 4004 positioned between a first free end 4020 and a second free end 4022 of the housing portions 220A, 220B. The female connector 4004 is configured to interlock with the male connector 4002, thereby connecting the top strap 140 and the bottom strap 150. The female connector 4004 is formed from a plastic core 210 that has penetrated the walls of the housing portions 220A, 220B. That is, the female connector 4004 is formed by a breakthrough internal molding process. The female connector 4004 is integrally formed within the housing portions 220A, 220B with the plastic core 210 and is a single unit. The female connector 4004 is positioned at the apex of the curvature of the bottom strap 150, which, in use, is positioned substantially above the user's ear. In some configurations, the female connector 4004 may be formed on a substantially straight portion of the bottom strap 150.

[0488] Figure 75A and Figure 75B This is a view of the male connector 4002 with top strap 140. As shown, the male connector 4002 extends outward and protrudes beyond the end of the housing 220. The male connector 4002 is formed of a plastic core 210, which is positioned beyond the end 4024 of the housing 220. The male connector 4002 includes a protrusion 4040 configured to interlock with a slot 4042 of the female connector 4004. The protrusion 4040 has a shape corresponding to the shape of the slot 4042, such that the male connector 4002 mates and engages with the female connector 4004 like a puzzle piece.

[0489] The protrusion 4040 includes a head 4050 and a handle 4052. The handle 4052 is an extension of the plastic core 210, positioned between the head 4050 and the end 4024 of the housing 220. The head 4050 is shown with a reverse arrow shape, which interlocks with the slot 4042 of the female connector 4004. The shape of the slot 4042 corresponds to and interlocks with the reverse arrow shape of the head 4050. The head 4050 is not limited to a reverse arrow shape; any interlocking shape can be used.

[0490] Figure 75B This is a side view of the top strap 140. As shown, the head 4050 has a thickness T1, and the shank 4052 has a thickness T2. The thickness T1 of the head 4050 is greater than the thickness T2 of the shank 4052. When the top strap 140 is attached to the bottom strap 150, the difference between thicknesses T1 and T2 allows the overmolded plastic to flow around the head 4050 of the male connector 4002. In some configurations, a narrower thickness T2 allows the head 4050 to be surrounded by the overmolded plastic material.

[0491] Figures 76A to 76CThese are various views of the female connector 4004 with top strap 150. The female connector 4004 has a triangular shape that extends radially outward and protrudes beyond the surfaces of the housing portions 220A, 220B. The female connector 4004 is formed of a plastic core 210 that breaks through the housing portions 220A, 220B during a breakthrough internal molding process. The female connector 4004 includes a protrusion 4046 in the shape of a tab, which is formed together with a slot 4042. Figure 76C As shown, the protrusion 4046 has a central region 4044 and a peripheral region 4048 extending outward from the central region 4044. The thickness T3 of the central region 4044 is greater than the thickness T4 of the peripheral region 4048. This greater thickness T3 of the central region increases the strength of the protrusion 4046 while allowing the overmolded plastic to flow around the protrusion 4046 when the top strap 140 and the bottom strap 150 are connected. The thickness T3 of the central region 4044 can be equal to the thickness T1 of the head 4050 of the male connector 4002.

[0492] A slot 4042 is formed within and extends through both the central region 4044 and the peripheral region 4048. The shape of the slot 4042 matches and interlocks with the reverse arrow shape of the head 4050. The slot 4042 opens in a direction away from the housing portions 220A, 220B, such that the head 4050 is inserted into and received by the slot. The slot 4042 is centrally positioned on the radially outermost portion of the peripheral region 4048. When the female connector 4004 is formed via a breakthrough injection molding process, the slot 4042 can be formed into the female connector 4004 and its shape determined to the shape of the female connector. In other configurations, the plastic core 210 can be removed from the female connector 4004 to form the slot 4042, for example, via a cutting process.

[0493] The slot 4042 is configured to receive at least the head 4050 of the male connector 4002, allowing the top strap 140 and bottom strap 150 to be connected and overmolded to form a permanent engagement between them. Specifically, the top strap 140 and bottom strap 150 are loaded into an overmolding tool, and the head 4050 is inserted into the slot 4052, connecting the male connector 4002 and the female connector 4004, and ensuring proper alignment of the top strap 140 and bottom strap 150. Once aligned, the overmolding tool is closed, and overmolding plastic material is injected into the tool to form a permanent overmolded engagement over the male connector 4002 and the female connector 4004. First, connect and align the straps 140 and 150, then overmold the male connector 4002 and female connector 4004. This improves the alignment accuracy of the straps and reduces the possibility of the straps 140 and 150 moving during the overmolding process, thereby improving the efficiency of the manufacturing process.

[0494] Figure 77A The diagram demonstrates aligning the male connector 4002 with the female connector 4004 before inserting the head 4050 into the slot 4042. Figure 77B The diagram shows that the head 4050 is inserted into and received by the slot 4042, thereby connecting the male connector 4002 and the female connector 4004. Figure 77C The thickness comparison of male connector 4002 and female connector 4004 is shown. The increased thicknesses T1 and T3 of the head 4050 of male connector 4002 and the central region 4044 of female connector 4004 are aligned to form upper surface 4060 and lower surface 4062, respectively. Upper surface 4060 and lower surface 4062 are configured to abut against the opposing inner surfaces of the mold cavity in the overmolding tool. This facilitates the alignment of top strap 140 and bottom strap 150 within the overmolding tool. Upper surface 4060 and lower surface 4062 are shown as flat, flat surfaces, but are not limited to this. Therefore, the opposing surfaces of the mold will have corresponding shapes to engage upper surface 4060 and lower surface 4062.

[0495] In some configurations, the size and shape of the head 4050 and slot 4052 can be determined such that a certain amount of clearance exists between them when the head 4050 and slot 4052 are engaged. A tight fit with no clearance between the male and female connectors may result in no space for the overmolded plastic material to flow between the connectors. This creates weak areas in the overmolded connection formed by gaps or voids within the overmolded joint, which may reduce the headband's durability. Figure 78A and Figure 78BThis shows the gap 4064 between the head 4050 and the slot 4052 when the male connector 4002 and the female connector 4004 are in the connected state. Figure 78B The gap in the middle is 4064 greater than Figure 78A The gap is 4064. In Figure 78A In the middle, the gap 4064 is very small, allowing the connection between the male connector 4002 and the female connector 4004 to have a tight fit, similar to a jigsaw puzzle piece. Figure 78B In the middle, the gap 4064 is relatively large, which allows the top strap 140 and bottom strap 150 to fit more loosely and be generally aligned within the overmolding tooling. The larger gap 4064 allows the overmolding plastic to flow between the connectors 140 and 150 to provide a robust engagement. Figure 78B In this configuration, the gap 4064 is preferably about 1.0 mm. In some configurations, the gap 4064 is between 0.1 mm and 1.0 mm.

[0496] Figure 79A An alignment recess 4070 is shown formed on the head 4050 of the male connector 4002, which is configured to receive an alignment pin 4072 positioned on the opposing inner surface of the mold cavity 4076 in the overlay molding tool portion 4074. Figure 79B A cover molding tooling portion 4074 is shown, having a mold cavity 4076 with a locating pin 4072 projecting from the surface of the mold cavity 4076. The locating pin 4072 is configured to be inserted into and received by a recess 4070, such that the head 4050 of the male connector 4002 is aligned and held in place within the mold cavity 4076 during positioning of the top and bottom straps 140 and during the cover molding process. The locating pin 4072 can restrict movement of the head 4050 within the mold cavity 4076. The locating pin 4072 can also inhibit or prevent the male connector 4002 from unlocking from the female connector 4004 before or during the cover molding process. In some configurations, the locating pin 4072 can hold the head 4050 in a position such that a gap 4064 between the male connector 4002 and the female connector 4004 is maintained.

[0497] In some embodiments, the recess 4070 and the locating pin 4072 may have corresponding shapes, sizes, and geometries. The recess 4070 is shown as a triangular recess formed at the inner corner of the head 4050, but is not limited thereto. The locating pin 4072 is shown as a cylindrical pin, but is not limited thereto. The triangular recess 4070 is configured to receive the locating pin 4072 in one of the vertices of the triangular recess, such as... Figure 79AAs indicated by the dashed circle in the diagram. The locating pin 4072 has cylindrical sides that are configured to abut against the side surface of the head 4050 so that the head 4050 of the male connector 4002 is aligned within the mold cavity 4076.

[0498] Figures 80A to 80C The top strap 140 and bottom strap 150 after the overmolding process are shown. As shown, an overmolded joint 4006 is molded over the male connector 4002 and female connector 4004, permanently bonding the top strap 140 and bottom strap 150 together. In some configurations, the overmolded joint 4006 may be formed of a plastic core 210, which is the same plastic core used to form the inner cores of both the top strap 140 and bottom strap 150, as well as the plastic cores of the male connector 4002 and female connector 4004. In other configurations, the overmolded joint 4006 may be formed of a different material, such as an elastomer.

[0499] like Figure 80A and Figure 80B As shown, the overmolded joint 4006 has a top edge 4056 that extends above the edge of the top strap 140 and extends to the surface of the top strap 140. That is, the overmolded joint 4006 overlaps with and is bonded to the housing 220 of the top strap 140. Similarly, the overmolded joint 4006 has a bottom edge 4058 that extends above the edge of the bottom strap 150 and extends to the surface of the bottom strap 150. That is, the overmolded joint 4006 overlaps with and is bonded to the housing 220 of the bottom strap 150. Bonding the overmolded joint 4006 to the top strap 140 and the bottom strap 150 increases the connection area between the overmolded joint 4006 and the top strap 140 and the bottom strap 150, thereby increasing the strength of the overmolded joint 4006. Furthermore, the overmolded joint 4006 extends beyond the end of the housing 220, thus enclosing the end of the housing 220 within the overmolded joint 4006, thereby improving the durability and appearance of the finished headband. In other words, the loose ends of the housing are closed and bonded within the overmolded joint 4006.

[0500] like Figure 80CAs shown, the thickness T of the overmolded joint 4006 is substantially equal to the thickness of the top strap 140 and the bottom strap 150, and also equal to the thickness of the male connector 4002 and the female connector 4004. That is, the thickness T of the overmolded joint 4006 is equal to the thickness T1 of the head 4050 and the thickness T3 of the central region 4044. Therefore, since the overmolded joint 4006, the top strap 140, and the bottom strap 150 have equal thickness, a continuous thickness is provided along the entire length of the straps 140 and 150, as well as in the connection and transition areas between the straps 140 and 150, which improves the aesthetics and comfort of the headband.

[0501] Connecting pieces using alignment posts

[0502] Figures 81A to 81C A bottom strap 150 is shown, formed by molding two empty textile shells 220 of bottom strap halves 150A and 150B together. The connecting strap halves 150A and 150B are shown against the background of the bottom strap 150, but are not limited to forming a bottom strap; they can be used to form any headband strap. The bottom strap 150 is formed by molding multiple textile shells 220 together using a single injection molding process to form a monolithic strap 150. The textile shells 220 are connected by a monolithic plastic core 210 formed within the two shells 220. A connecting tab 4008 is positioned between the free ends 4026 of the shells 220 and is formed of the plastic core 210. Connecting tab 4008 extends between the two strap halves 150A, 150B and provides a central injection point 4010 for injection of the strap halves using plastic core material 210. Connecting tab 4008 is configured for overmolding to provide a clean and durable joint between the strap halves 150A, 150B. Any excess material or gate formed at the injection point is trimmed off prior to overmolding.

[0503] The end portion of the connecting piece 4008 includes a pair of alignment posts 4078 that project and extend from the upper surface 4018 and lower surface 4028 of the connecting piece 4008 in opposite directions (e.g., the thickness direction). The alignment posts 4078 are shown as, but not limited to, rectangular protrusions that extend across the width of both the upper surface 4018 and the lower surface 4028 of the connecting piece 4008. The alignment posts 4078 are configured to abut against the inner surface of the mold cavity of the overmolding tool, such that the ends 4026 of the strap halves 150A, 150B are aligned within the overmolding tool (e.g., in the thickness direction of the strap).

[0504] Figure 81CAlignment posts 4078 are shown extending from the upper surface 4018 and lower surface 4028 of the connecting tab 4008. The connecting tab 4008 is shown to have a thickness T6. The region of the connecting tab 4008 including the alignment posts 4078 has a thickness T5. The thickness T5 of the region including the alignment posts 4078 is greater than the thickness T6 of the region without the alignment posts 4078. The alignment posts 4078 can also maintain a gap between the upper surface 4018 and lower surface 4028 of the connecting tab 4008 and the inner surface of the mold cavity, which allows the overmolded plastic to flow over the connecting tab 4008 to provide a robust joint.

[0505] Figure 81D and Figure 81E The strap halves 150A and 150B are shown following the overmolded connecting tab 4008. As shown, the overmolded member 4080 is formed above the connecting tab 4008. The overmolded member 4080 may be formed of the same material as or a different material from the bottom strap 150 (e.g., plastic core 210). In some embodiments, the overmolded member 4080 may include an elastomeric material to provide a flexible and comfortable contact between the overmolded member 4080 and the patient's head. The overmolded member includes an outer surface 4082 and an inner surface 4084, the outer surface being configured to face away from the patient's head in use, and the inner surface being configured to contact the patient's head in use.

[0506] Figure 81D This is a top view of the overlay molding 4080, showing the top surface 4082 of the overlay molding 4080 facing away from the patient's head. Figure 81E This is a bottom view of the overmolding 4080, showing the bottom surface 4084 of the overmolding 4080 facing the patient's head. A positioning mark 4088 indicating the position of the alignment post 4078 may be formed in or on surfaces 4082 and 4084 of the overmolding 4080. The positioning mark 4088 is visible through surfaces 4082 and 4084 because the thickness of the overmolding 4080 is equal to the thickness T5 of the alignment post 4078. In other configurations, the thickness of the overmolding 4080 may be greater than the thickness T5 of the alignment post 4078, making the alignment post 4078 invisible through surfaces 4082 and 4084 of the overmolding 4080. That is, the outer surface 4082 of the overmolding 4080 may be smooth and continuous, making the positioning mark 4088 indicating the position of the alignment post 4078 invisible.

[0507] Product labels or trademarks 4086 may also be formed in or on the outer surface 4082 of the overmolding member 4080. During the overmolding process, the trademark 4086 is molded into the surface 4082. In some configurations, alignment posts 4078 may be configured to form part of the trademark 4086. For example, in the illustrated configuration, one alignment post 4078 may have a shape including the letter "F," while another alignment post may have a shape including the letter "P." The thickness of the alignment posts 4078 and / or the overmolding member 4080 may be varied so that the alignment posts 4078 are visible on the surface 4082. In other configurations, the trademark 4086 may be formed using finishing processes (e.g., engraving, molding, stamping, etc.).

[0508] In some embodiments, connecting tabs 4008 can be trimmed between the alignment posts 4078 prior to overmolding. This allows the overall length of the bottom strap 150 to be adjusted by increasing or decreasing the spacing between the alignment posts 4078, and thus increasing or decreasing the length of the overmolded component. That is, in some configurations, the distance between the alignment posts 4078 (e.g., in the longitudinal direction of the bottom strap 150) can be shortened or lengthened to shorten or lengthen the overall length of the bottom strap 150. This method can be used to provide different headband sizes using the same bottom strap component.

[0509] Injection housing

[0510] Figures 82A to 83E The image shows a headband end joint housing 4090, into which the ends 4026 of the empty bottom headband halves 150A and 150B are inserted and internally molded to form an integral bottom headband 150. The connecting headband halves 150A and 150B are shown against the background of the bottom headband 150, but are not limited to forming a bottom headband; they can be used to form any headband. The bottom headband 150 is formed by molding it internally with multiple textile shells 220 using a single-injection molding process to form an integral headband. Therefore, the textile shells 220 are connected by an integral plastic core 210 formed within and extending through both shells.

[0511] The housing 4090 has an internal cavity 4092 configured to receive the open ends 4026 of two textile housings 220. The housing 4090 may have a shape, size, and geometry corresponding to the shape, size, and geometry of a region within the internal cavity of the internal molding tool, such that the housing 4090 fits securely within the internal molding tool. Therefore, the housing 4090 can be aligned relative to the cavity of the internal molding tool, allowing the ends 4026 of the textile housings 220 to be aligned by the housing 4090 when in the internal molding tool. The housing 4090 is not limited to a rectangular shape or geometry.

[0512] The housing 4090 has an injection port 4094 on at least one side, which provides a channel through which internal molded plastic material 210 can be injected and flow. In some configurations, the injection port 4094 may be located on multiple sides of the housing 4090. Figure 83E Injection holes 4094 are shown on opposite sides of the housing 4090. The plastic core material 210 can be injected into both holes 4094 simultaneously, or alternatively, one hole 4094 can be blocked while the plastic material 210 is injected into the other hole 4094.

[0513] like Figure 83D As shown, injection port 4094 is fluidly connected to internal chamber 4092, which receives the open end 4026 of textile housing 220. End 4026 of textile housing 220 opens toward injection port 4094, allowing fluid communication between the internal cavity of textile housing 220 and injection port 4094. During the internal molding process, plastic is injected into textile housing 220 using internally molded plastic core 210 injected into the port 4094 of housing 4090. Internally molded plastic core 210 flows from port 4094 to internal chamber 4092, and then from internal chamber 4092 back into textile housing 220. Housing 4090 provides a central injection point for internally molding textile housing 220. In some configurations, housing 4090 may provide an alternative of overmolding a molded joint over the end of textile housing 220. Therefore, the loose ends of the textile outer shell 220 are closed and housed within the shell 4090, which improves the aesthetics and durability of the headband.

[0514] The internal chamber 4092 has an inner cavity region 4092A located in the central region of the housing 4090. The inner cavity region 4092A has one end opening toward and leading to an injection port 4094, and a second end opening toward and leading to an outer cavity region 4092B. That is, the inner cavity region 4092A is positioned between the injection port 4094 and the outer cavity region 4092B. The injection port 4094 guides the injected plastic material 210 into the inner cavity region 4092A of the internal chamber 4092. An end portion of the housing 220 abuts the inner wall of the outer cavity region 4092B, which provides a fluid path from the injection port 4094 into the cavity of the housing 220, allowing the injected plastic material 210 to flow from the injection port 4094 into the textile housing 220.

[0515] The height D1 of the inner cavity region 4092A is less than the height D2 of the outer cavity region 4092B. The difference between the height D1 of the inner cavity region 4092A and the height D2 of the outer cavity region 4092B creates a stepped profile within the inner cavity 4092, which allows the ends 4026 of the textile outer shell 220 to be spaced apart when positioned within the housing 4090. The height D1 of the inner cavity region 4092A can be substantially equal to the thickness of the core material 210 passing through the textile outer shell 220.

[0516] In some configurations, the length L of the inner cavity region 4092A (e.g.) Figure 83D (As shown) can be varied so that different lengths of the bottom strap 150 can be formed from the same textile shell 220. That is, different lengths of bottom straps can be formed from a textile shell 220 of a fixed length by changing the length of the shell 4090. The length L of the inner cavity region 4092A causes the ends 4026 of the textile shell 220 to be spaced closer or further apart, which increases or decreases the final length of the strap 150. For example, in some configurations, the bottom straps 150 for medium and medium-to-large headbands can be formed using a textile shell 220 of the same length and a shell 4090 with an inner cavity region 4092A of different lengths L. That is, the difference in length between the medium and medium-to-large bottom straps 150 is provided by the difference in the length L of the inner cavity region 4092A.

[0517] Strap cross section

[0518] Figure 84A and Figure 84BA cross-sectional view of the top strap 140 and bottom strap 150 after an internal molding process in which the textile outer shell 220 is filled with a plastic core 210 is shown. Both the top strap 140 and the bottom strap 150 have an inner surface 4066 and an outer surface 4068, wherein the inner surface 4066 is configured to contact the patient's head, and the outer surface 4068 is configured to face away from the patient's head. In this embodiment, the plastic core 210 of the straps 140, 150 has a substantially D-shaped cross-section, such that the outer surface 4068 has a convex curvature, and the inner surface 4066 has a substantially flat, flat, or straight profile. In some configurations, the inner surface 4066 may have a concave curvature.

[0519] The flat profile of the inner surface 4066 is configured to have an increased contact area with the patient's head, allowing for a more even (compared to a convex profile) distribution of any load across the headband. This improves the stability of the headband and patient comfort. The convex curvature of the outer surface 4068 provides a degree of rigidity to the strap and also gives the headband a soft or aesthetically pleasing appearance.

[0520] Soft edges of the straps

[0521] Figure 84A A top strap 140 and a bottom strap 150 with a plastic core 210 are shown. These straps include a flange portion 4036 on the outer edge of a padded textile shell 220. The flange portion 4036 provides a hard and rigid edge treatment for the top strap 140 and the bottom strap 150. Figure 84B The top strap 140 and bottom strap 150 are shown, featuring soft edge portions 4038 formed by the absence of a plastic core 210 within these soft edge portions 4038. The soft edge portion 4038 is a portion of the outer shell 220 that is unfilled with the plastic core 210, allowing the textile outer shell 220 to remain supple and flexible. Therefore, the soft edge portion 222 provides a soft or cushioned edge to the top strap 140 and bottom strap 150, which is not only comfortable against the user's skin but also aesthetically pleasing.

[0522] In some configurations, the soft edge portion 4038 is formed such that the edges of the tubular housing 220 are crimped before the injection of the plastic core 210, thereby inhibiting or restricting the flow of the plastic core 210 into the crimped portions of the housing 220. These edges are crimped by a portion of the molding tool adjacent to the mold cavity. The depth to which the molding tool crimps the edges of both the top strap 140 and the bottom strap 150 can vary along the lengths of the top strap 140 and the bottom strap 150, such that the width of the plastic core 210 ( Figure 84Aand Figure 84B The width of the plastic core 210 (in the horizontal direction) can vary along the length of the top strap 140 and the bottom strap 150. Therefore, the width of the plastic core 210 can be wider in different areas of both the top strap 140 and the bottom strap 150 to reinforce those areas and provide additional strength. Similarly, in some configurations, the width of the plastic core 210 can be narrower in certain areas along the length of both the top strap 140 and the bottom strap 150 to provide flexibility in those narrower areas. Those skilled in the art will understand that the shape and geometry of the plastic core can be varied to provide strength and stiffness to the top strap 140 and the bottom strap 150 in desired directions.

[0523] Figure 85 A top strap 140 is shown attached to a bottom strap 150, which has a soft edge portion 4038 extending along its length. The bottom strap 150 has a wavy, curved shape to form an ear arch region 4016 positioned above the user's ear during use. As shown, the width W1 of the soft edge portion 4038 at the ear arch region 4016 is greater than the width W2 of the soft edge portion 4038 at the rest of the bottom strap 150. The increased width of the soft edge portion 4038 in the ear arch region 4016 relative to the rest of the bottom strap 150 provides increased softness / cushioning and comfort where the ear arch region should come into contact with the patient's ear during use. The user's ear arch region is a sensitive area, and contact with it may cause discomfort.

[0524] In some configurations, the headband may include a four-point connection configuration with an upper and / or lower strap (or other configurations). In such configurations, any strap located near the patient's ear during use may include an increased width of soft edges.

[0525] Combined top and back straps with overmolded connection

[0526] Figure 86A headband arrangement 5000 is shown, comprising a rear strap portion 140 and a top strap portion 150, which are integrally formed as a single halo or rear headband loop strap 5002. The headband loop strap 5002 is connected to a front strap 5004 via an overmolded engagement 5006. The front strap 5004 is formed separately from the headband loop strap 5002 and then connected to the rear headband loop 5010 via an overmolded engagement. The front strap 5004 may include an internally molded strap portion, a braided filament housing for a locking mechanism, or a combination of both. In one embodiment, the front strap 5004 of the headband arrangement 5000 may be configured to include a size adjustment mechanism comprising a locking mechanism and filaments. This is advantageous because it allows the braided strap to accommodate filaments to be manufactured and to be tested as a separate component. This reduces the complexity of manufacturing these components and prevents the headband or a large portion of the headband from being wasted if the tolerance or operation of the locking mechanism is compromised and / or defective. In other words, since the front strap 5004 is formed separately from the headband loop strap 5002, there is no need to scrap the entire headband if the locking mechanism is faulty or defective.

[0527] The ends of the headband loop 5002 are connected together by a molded overlay 5008 to form a rear headband loop 5010 (indicated by a dotted line) that receives or covers the back of the patient's head like a cup. The molded overlay 5008 is located at the top of the patient's head during use. Positioning the molded overlay 5008 at the top of the patient's head is advantageous because the top of the user's head does not contact the bed or pillow, which could exert force on the overlay 5008 and cause it to embed into the patient's head. In other words, positioning the molded overlay 5008 at the top of the patient's head may provide greater patient comfort.

[0528] like Figure 87A As shown, the headband loop 5002 is formed from a single internally molded component that combines the top strap 140 and the rear strap 150. The headband loop 5002 is formed from a single-length textile outer shell material 220 filled with a plastic core material 210. The headband loop 5002 includes alignment tabs 5020 formed at and extending from the free ends of the top strap portion 140. The headband loop 5002 also includes a breakout tab 5030 positioned between the top strap portion 140 and the bottom strap portion 150.

[0529] Alignment patch 5020 is basically similar to Figures 81A to 81EThe connecting tab 4008 is included. The alignment tab 5020 is formed of a plastic core 210 and is configured to align the ends of the headband loop 5002 within an overmolding tool used to form an overmolded joint between the top strap portions 140. Connecting the ends of the top strap portions 140 forms a closed loop of the rear headband loop 5010.

[0530] The alignment tab 5020 includes alignment posts 5022 configured to align the end of the top strap portion 140 within the overlay molding tool. Figure 88A and Figure 88B As shown, the alignment post 5022 also has a raised abutment surface 5024 configured to abut, engage, and / or contact the inner wall of the overmolding tool cavity, and to align the alignment tab 5020 within the tool (e.g., in the thickness, width, and / or longitudinal direction of the headband loop strap 5002). Similar to the connecting tab 4008, when the alignment tab 5020 is aligned within the overmolding tool, the alignment tab 5020 is overmolded to connect the ends of the headband loop strap 5002.

[0531] The headband loop strap 5002 includes two protruding tabs 5030 configured to be molded together with the end of the front strap 5004. The protruding tabs 5030 are substantially similar to the male connector 4002 in the preceding embodiments. Figure 89A and Figure 89B As shown, the breakout tab 5030 includes a head portion 5032 that engages and interlocks with a feature of the overmolded connection 5006, thereby connecting the headband loop strap 5002 and the front strap 5004. The head portion 5032 consists of a protrusion forming a raised abutment surface 5034. The abutment surface 5034 is configured to abut, engage, and / or contact the inner wall of the overmolded tool cavity, and to align with the breakout tab 5030 within the tool (e.g., in the thickness, width, and / or longitudinal direction of the headband loop strap 5002). The abutment surface 5034 is flush with the outer surface 5008 of the overmolded connection 5006 to provide a smooth transition between the headband loop strap 5002 and the front strap 5004.

[0532] The headband loop 5002 and the front strap 5004 are connected by an overmolded fitting 5006 formed over the end portions of the protruding tab 5030 and the front strap 5004. In some configurations, the overmolded fitting 4006 may be formed of the same material as the plastic core 210 used to form the inner core of the headband loop 5002. In other configurations, the overmolded fitting 5006 may be formed of a different material, such as an elastomer.

[0533] like Figure 89A and Figure 89B As shown, the head portion 5032 of the breakout tab 5030 is surrounded and held within the overmolded engagement 5006. A locking hole 5036 is formed within the overmolded engagement 5006 and configured to secure the front strap 5004 in place. The locking hole 5036 is formed into the overmolded engagement 5006 through a protrusion projecting from the inner wall of the overmolding tool cavity.

[0534] In some configurations, the headband loop strap 5002 and the front strap 5004 can be connected by a connector that engages with the push-pull tab 5030 and the end portion of the front strap 5004. Thus, while securing the end portion of the front strap 5004, the connector can also engage the head portion 5032 of the push-pull tab 5030, thereby connecting the headband loop strap 5002 and the front strap 5004.

[0535] Alignment pins, pin holes, and embossed recesses

[0536] Figures 90A to 92D Internally molded top straps 140 and bottom straps 150 are shown, including alignment posts 5102 protruding through a textile housing 220 and alignment recesses or pin holes 5104 recessed into the textile housing 220. Alignment posts 5102 are configured to abut against an inner surface of the overmolding tool cavity, similar to male connector head 4002 and alignment tab 5020. Alignment posts 5102 align and position the ends of the straps within the overmolding tool. Alignment posts 5102 protrude from at least one of the top surface 5112 and bottom surface 5114 of the top strap 140 and bottom strap 150. Alignment posts 5102 protrude through the textile housing 220. Alignment posts 5102 are formed into the textile housing 220 during the internal molding of the top straps 140 and bottom straps 150. Figure 90B and Figure 90D Alignment posts 5102 formed on the breakthrough tab 5120 are shown. The alignment posts 5102 of the breakthrough tab 5120 are formed of plastic core material 210 and are substantially similar to the alignment posts 5022 of the alignment tab 5020.

[0537] The user-facing surface (or bottom surface) 5114 includes pin holes 5104 that are partially recessed into the thickness of the straps 140, 150. The pin holes 5104 are configured to receive pins that protrude, for example, from the surface of an internal cavity of the overlay molding tool. The pins and pin holes 5140 are substantially similar to... Figures 79A to 79CThe top strap 140, 150 has a recess 4070 and a positioning pin 4072. The pin engages with a pin hole 5104 to hold the straps 140, 150 in a predetermined position and align them within the overmolding tool, thereby inhibiting movement of the inner molded straps 140, 150 within the overmolding tool during injection of the overmolded plastic. The pin hole 5104 is formed on the bottom surface 5114 so as to be invisible when worn by a user. In some configurations, the pin hole 5104 may be formed in one or both of the top surface 5112 and the bottom surface 5114 of the top strap 140 and the bottom strap 150. In some configurations, the depth of the pin hole 5104 may be less than the thickness of the top strap 140 and the bottom strap 150. In some configurations, the depth of the pin hole 5104 may be equal to the thickness of the top strap 140 and the bottom strap 150.

[0538] The ends of the breakout tab 5120, top strap 140, and bottom strap 150 all include embossed recesses on the inner surface 5112 and outer surface 5114. These embossed recesses 5106 are recessed into the plastic core 210 of the breakout tab 5120 and into the textile housing 220 at the ends of the top strap 140 and bottom strap 150. Figures 91A to 91D As shown, the embossing 5106 is configured to provide increased thickness and increased surface area in the region of the overmolded joint 5130 that engages with the embossing, so as to form a mechanical connection between the overmolded joint 5130 and the straps 140, 150. The increased surface area provided by the embossing 5106 improves the strength of the overmolded joint 5130.

[0539] Figures 92A to 92D The top strap 140 and bottom strap 150 are shown after a cover-molded joint 5130 is formed over the ends of the breakout tab 5120, top strap 140, and bottom strap 150. The cover-molded joint 5130 provides a permanent cover-molded connection over the top strap 140 and bottom strap 150. The cover-molded joint 5130 is formed in a manner similar to the cover-molded joints previously described. Since the alignment post 5102 has the same thickness as the cover-molded joint 5130, it is possible to form a positioning mark in the cover-molded joint 5130. In some configurations, a trademark 5150 may be formed into the cover-molded joint 5130. Figure 92C and Figure 92D The increased thickness of the overmolded joint material provided by the embossing 5106 is shown. The overmolded joint 5130 also overlaps with the edge of the bottom strap 150 to increase the strength of the joint between the top strap 140 and the bottom strap 150.

[0540] In some configurations, a molded overlay connector 5140 may be provided on the free end of either of the straps 140, 150. The molded overlay connector 5140 is formed similarly to the molded overlay engagement 5130 and may engage the alignment post 5102 and the recess 5106 of the straps 140, 150. The connector 5140 may include a ring or clamp configured for attachment to another headband or face mask component.

[0541] The following disclosure relates to a headband assembly 8000 for a patient interface 8002, which is configured to deliver respiratory therapy to a patient or user. Figures 93A to 93C A non-limiting exemplary embodiment of a patient interface 8002 is shown, which includes a headband assembly 8000 and a mask assembly 8004. The mask assembly 8004 can be any suitable arrangement for delivering a flow of breathing gases to the airway of a patient or user. The mask assembly 8004 may include a body and one or more sealing pads. In some configurations, the body is more rigid than the one or more sealing pads. In some configurations, the body and one or more pads are formed integrally or monolithically. The sealing pads are configured to form a seal with one or both of the patient's or user's nose and mouth. The mask assembly 8004 can be, for example, but not limited to, an over-the-nose full-face mask, a under-the-nose full-face mask, a nasal mask, a nasal pillow, or a nasal cannula. Therefore, the mask assembly 8004 is indicated by a dashed box in the figures.

[0542] The headband assembly 8000 includes a headband 8006 and at least one connector 8008. In the illustrated arrangement, the at least one connector 8008 includes a first connector 8008 and a second connector 8008 (not shown). The headband assembly 8000 is substantially symmetrical about the sagittal plane of the user. Therefore, the second connector 8008 can be a mirror image of the illustrated first connector 8008, so the description of the first connector 8008 can be equally applied to the second connector 8008. Similarly, the left side (from the patient's or user's perspective) of the headband 8006 can be a mirror image of the right side. The first connector 8008 and the second connector 8008 are each connected to the face mask assembly 8004 at a front portion 8008a and to the headband 8006 at a rear portion 8008b. In some configurations, the first connector 8008 and the second connector 8008 can be coupled to each other, or they can be an integral or monolithic construction.

[0543] The headband 8006 may include one or more of a top or vertical strap 8010, a front or forehead strap 8012, a back or rear strap 8014, and an ear loop 8016. The front strap 8012 substantially crosses the front of the user's head. That is, the front strap 8012 may be located at the front of the top of the head, such as on the forehead. The top strap 8010 substantially crosses the top of the user's head. The top strap 8010 and the front strap 8012 converge at a connection 8020. The connection 8020 may be attached to or form part of the ear loop 8016. The rear strap 8014 substantially passes around the back of the user's head. That is, the rear strap 8014 may be located behind the top of the head. In some configurations, the end of the rear strap 8014 forms part of the ear loop 8016. The ear loop 8016 partially or completely encircles the user's ears. In the illustrated arrangement, the periauricular ring 8016 completely surrounds the user's ear and forms a closed loop. The periauricular ring 8016 includes at least one connector connection surface 8022, allowing the headband 8006 to be connected to the first connector 8008 and / or the second connector 8008.

[0544] The first connector 8008 and / or the second connector 8008 include at least one strap or other structure extending between the mask assembly 8004 and the headband 8006. In the illustrated arrangement, one or both of the first connector 8008 and / or the second connector 8008 include a first strap 8024 and a second strap 8026. Strap 8026 is referred to herein as the lower strap 8026. Strap 8024 is referred herein as the middle strap 8024 because it is vertically positioned between the lower strap 8026 and the front strap 8012 and / or the top strap 8010. In use, the middle strap 8024 extends from the front portion 8008a and the mask assembly 8004 above and behind the user's ears. In use, the lower strap 8026 extends from the front portion 8008b and the mask assembly 8004 below and behind the user's ears. The middle strap 8024 meets the lower strap 8026 at the rear portion 8008b. In the configuration shown, the middle strap 8024 and the lower strap 8026 are integrally formed.

[0545] In at least one embodiment, the first connector 8008 and / or the second connector 8008 may include a middle strap in addition to the straps 8024 and 8026, or may include a middle strap instead of the two straps. The middle strap may extend from the front portion 8008a and the mask assembly 8004 to above and behind the user's ear. In at least one embodiment, the middle strap may extend from the front portion 8008a and the mask assembly 8004 to below and behind the user's ear. In at least one embodiment, the middle strap may extend from the front portion 8008a and the mask assembly 8004 and then spread out, such that it extends both above and behind the user's ear, and also below and behind the user's ear.

[0546] Figure 93B A perspective view of the headband assembly 8000 is shown, in which the first connector 8008 is disconnected from the headband 8006. In use, the first connector 8008 can be disconnected from the headband 8006 and extends outward around the ears to release the face mask assembly 8004 from the user's face. The second connector 8008 (not shown) can be disconnected in a similar manner to completely disconnect the face mask assembly 8004. In some embodiments, the front portion 8008a of the first connector 8008 and / or the second connector 8008 can remain connected to the face mask assembly after the face mask assembly 8004 has been removed.

[0547] When the mask assembly 8004 and connector 8008 are disconnected from the headband 8006, the user can wear the headband 8006 independently before needing to reconnect the mask assembly 8004. That is, the headband 8006 is preferably configured to provide stable support to the user's head without relying on the mask assembly 8004 and / or connector 8008 to maintain proper position, at least when the user's head is relatively upright. To reconnect the mask assembly 8004, one of the first connector 8008 and / or the second connector 8008 is connected to the headband 8006 at the relevant periauricular ring 8016. The mask assembly 8004 is positioned in the desired location. Then, the other of the first connector 8008 and / or the second connector 8008 is connected to the headband 8006 at the other periauricular ring 8016.

[0548] Figure 93CA perspective view of a headband assembly 8000 is shown, in which a first connector 8008 is connected to a headband 8006. A headband connection surface 8030 on the first and / or second connector 8008 facilitates connection between the first and / or second connector 8008 and the headband 8006. As described above, a connector connection surface 8022 on the headband 8006 facilitates connection between the headband 8006 and the first and / or second connector 8008. The connector connection surface 8022 and the headband connection surface 8030 allow the first connector 8008 and / or the second connector 8008 to be removably connected to the headband 8006. The headband connection surface 8030 and the connector connection surface 8022 include mating or complementary shapes. In some configurations, multiple portions of each of the headband connection surface 8030 and the connector connection surface 8022 have the same shape or are configured to overlap each other when both the headband 8006 and the connector 8008 are properly positioned. See also Figure 93C As an example, the connector connecting surface 8022 of the headband 8006 is curved along a portion of the periauricular ring 8016. The headband connecting surface 8030 is a mating curve on the first connector 8008. The connector connecting surface 8022 and the headband connecting surface 8030 mate to connect the first connector 8008 and the headband 8006.

[0549] In some embodiments, the first connector 8008 and the second connector 8008 are connected to the headband 8006 using a connection system. In at least one embodiment, this is a hook-and-loop connection system including hook-and-loop fasteners. One component of the connection system is located on the headband connection surface 8030, while another component is located on the connector connection surface 8022. The hook-and-loop connection system is configured to hold the headband connection surface 8030 in proper position around the user's ears while the patient interface 8002 is in use. The connection system allows for easy disconnection of the mask assembly 8004, the first connector 8008, and / or the second connector 8008 when needed by the user. Furthermore, the connection system allows for easy reconnection of the mask assembly 8004, the first connector 8008, and / or the second connector 8008 to the headband 8006 when needed.

[0550] Other configurations of the headband assembly 8000 include a magnetic connection system between the headband 8006 and the connector 8008. Some configurations include one or more magnets near or above the connector connection surface 8022. In these configurations, the headband connection surface 8030 may include one or more ferrometallic structures. Thus, as shown, the connector connection surface 8022 and the headband connection surface 8030 can represent components of the magnetic connection system. Therefore, the connector 8008 and the headband 8006 are connected by magnetic attraction between the magnets of the connector connection surface 8022 and the ferrometallic structures of the headband connection surface 8030. Alternatively, the headband connection surface 8030 may provide one or more magnets, while the connector connection surface 8022 may provide one or more ferrometallic structures.

[0551] In an alternative configuration, the first connector 8008 and / or the second connector 8008 may include one or more magnets near or above the headband connection surface 8030, and the headband 8006 may include one or more magnets near or above the connector connection surface 8022. The one or more magnets on the connector connection surface 8022 may be oriented such that their polarities are substantially opposite to those of the magnets on the headband connection surface 8030. This configuration ensures that magnetic repulsion indicates incorrect attachment.

[0552] The magnetic connection system is largely self-aligning. This helps the user to connect the headband 8006 and the first connector 8008 and / or the second connector 8008 in the same position each time they try it on. Therefore, the magnetic connection system allows the mask assembly 8004 and the connector 8008 to be easily put on and taken off.

[0553] In at least one embodiment, the connector connecting surface 8022 and the headband connecting surface 8030 overlap when connected. In at least one embodiment, the connector connecting surface 8022 and the headband connecting surface 8030 are adjacent, such that these surfaces are complementary. For example, the headband connecting surface 9030 and the connector connecting surface 9022 may overlap along a connecting area, which may be C-shaped and extend from above and below the user's ear.

[0554] In at least one embodiment, the middle strap 8024 and the lower strap 8026 of the first connector 8008 and / or the second connector 8008 are adjustablely connected to the mask assembly 8004. The middle strap 8024 and the lower strap 8026 can pass through corresponding holes in the mask assembly 8004 and then fold back onto themselves or each other to be adjusted and secured in place. In at least one embodiment, the middle strap 8024 and the lower strap 8026 are fixedly connected to the mask assembly 8004. In at least one embodiment, the middle strap 8024 is fixedly connected to the mask assembly 8004, while the lower strap 8026 is adjustablely connected to the mask assembly 8004. In at least one embodiment, the lower strap 8026 is fixedly connected to the mask assembly 8004, while the middle strap 8024 is adjustablely connected to the mask assembly 8004.

[0555] Disconnecting the mask assembly 8004 from the headband 8006 using the first connector 8008 and / or the second connector 8008 allows the mask assembly 8004 to be removed without adjusting the sizing of the headband assembly 8000. The mask assembly 8004 can be repositioned via the first connector 8008 and / or the second connector 8008 without sizing adjustment. This simplifies the process of putting on and taking off the mask.

[0556] In some configurations of the headband assembly 8000, the top strap 8010, front strap 8012, rear strap 8014, or any combination of these straps, includes an adjustment mechanism 8040. This adjustment mechanism can be any suitable arrangement, such as a buckle. Opposite portions of the straps 8010, 8012, and 8014 can pass through the buckle and fold over themselves. The free ends of the straps 8010, 8012, and 8014 can be secured to the remainder of the straps 8010, 8012, and 8014 using suitable fasteners, such as hook-and-loop fasteners.

[0557] In at least one embodiment, the top strap 8010 and the front strap 8012 form separate portions of the periauricular ring 8016. Multiple portions of the periauricular ring 8016 defined by the top strap 8010 and the front strap 8012 may be connected to each other below and / or above the user's ear.

[0558] In at least one embodiment, the headband 8006 includes a top strap 8010 that crosses the top of the user's head and a rear strap 8014 that crosses the back of the user's head.

[0559] In at least one embodiment, the first connector 8008 may be fixedly connected to the headband 8006. In this configuration, the second connector 8008 may be disconnected from the headband 8006 to remove the face mask assembly 8004.

[0560] Figures 94A to 94C A perspective view of a patient interface 9002 is shown, which includes a headband assembly 9000 and a face mask assembly 9004. The headband assembly 9000 includes a headband 9006, a first connector 9008, and a second connector 9008 (not shown). As shown in... Figures 93A to 93C In this embodiment, the headband assembly 9000 may be symmetrical about the user's sagittal plane. Undisclosed details of the headband assembly 9000 may be the same as or similar to corresponding elements of the headband assembly 8000, or may be another suitable arrangement. In this embodiment, the headband assembly 9000 includes a portion of a periauricular ring 9016. Figure 94C The first connector 9008 and the second connector 9008 are each connected to the mask assembly 9004 at the front portion 9008a and to the headband 9006 at the rear portion 9008b.

[0561] The headband 9006 includes a top or vertical strap 9010, a front or forehead strap 9012, and a rear or back strap 9014. The front strap 9012 substantially crosses the front of the user's head. The top strap 9010 substantially crosses the top of the user's head. The back strap 9014 substantially wraps around the back of the user's head. The headband 9006 includes a connector connection surface 9022, allowing the headband 9006 to connect to a first connector 9008 and / or a second connector 9008.

[0562] The first connector 9008 and / or the second connector 9008 include a central strap 9024 and a lower strap 9026. The central strap 9024 extends from the front portion 9008a and the mask assembly 9004 to above and behind the user's ear. The lower strap 9026 extends from the front portion 9008a and the mask assembly 9004 to below and behind the user's ear. The central strap 9024 meets the lower strap 9026 at the rear portion 9008b. In the illustrated configuration, the central strap 9024 and the lower strap 9026 are integrally formed.

[0563] In at least one embodiment, the first connector 9008 and / or the second connector 9008 may include a central strap. The central strap may extend from the front portion 9008a and the mask assembly 9004 to above and behind the user's ear. In at least one embodiment, the central strap may extend from the front portion 9008a and the mask assembly 9004 to below and behind the user's ear. In at least one embodiment, the central strap may extend from the front portion 9008a and the mask assembly 9004 and then spread out, such that it extends both above and behind the user's ear, and also below and behind the user's ear.

[0564] Figure 94B A perspective view of the headband assembly 9000 is shown, in which the first connector 9008 is disconnected from the headband 9006. In use, one or both of the connectors 9008 can be disconnected from the headband 9006 and extend outward around the ears to release the mask assembly 9004 from the user's face.

[0565] Headband connection surfaces 9030 on the first connector 9008 and / or the second connector 9008 facilitate connection between the first and / or second connectors 9008 and the headband 9006. Connector connection surfaces 9022 on the headband 9006 facilitate connection between the headband 9006 and the first connector 9008 and / or the second connector 9008. Connector connection surfaces 9022 and 9030 allow the first connector 9008 and / or the second connector 9008 to be removably connected to the headband 9006. Headband connection surfaces 9030 and 9022 include mating or complementary shapes. Figures 94A to 94C In the illustrated embodiment, both the headband connection surface 9030 and the connector connection surface 9022 are significantly reduced in size. The headband connection surface 9030 and the connector connection surface 9022 are shifted rearward and vertically from the user's ear (e.g., above) and then connected along a connecting line, which can be, for example, straight or slightly curved. In some configurations, the complete connection between the headband connection surface 9030 and the connector connection surface 9022 is located above the lowest point of the user's ear.

[0566] In at least one embodiment, the first connector 9008 may be fixedly connected to the headband 9006. In this configuration, the second connector 9008 may be disconnected from the headband 9006 to remove the face mask assembly 9004.

[0567] In at least one embodiment, the first connector 8008, 9008 and / or the second connector 8008, 9008 are made of a continuous soft fabric cover having a plastic core. In some configurations, the plastic core may be an internally molded plastic core, wherein molten plastic is introduced into and cooled in spaces between or within multiple fabric portions or layers. In other embodiments, the first connector 8008, 9008 and / or the second connector 8008, 9008 may be made of a rigid polymer material. In at least one embodiment, the first connector 8008, 9008 and / or the second connector 8008, 9008 may be made of a soft polymer material such as silicone. In at least one embodiment, the first connector 8008, 9008 and / or the second connector 8008, 9008 may be made of at least one rigid polymer material and at least one soft polymer material. Some embodiments may include the use of a fabric material. In at least one embodiment, the first connector 8008, 9008 and / or the second connector 8008, 9008 may comprise a combination of rigid polymer material, flexible polymer material, ceramic material, fabric material, foam material and / or metal material. In at least one embodiment, the first connector 8008, 9008 and / or the second connector 8008, 9008 may be made of a foam and fabric composite material.

[0568] Closed loop headband

[0569] Figure 95 and Figure 96 The front and rear perspective views of a patient interface 9100 are shown, which includes a headband 9102, a face mask assembly 9104, and a connector 9106. The headband 9102 is a closed-loop headband design, with no breaks in the loop formed by the headband 9102 and the face mask assembly 9104. As shown in the figures, the upper strap 9108 and the lower strap 9110 are formed from a single continuous strap. Therefore, the upper strap 9108 and the lower strap 9110 form a closed-loop connection or continuous connection between the headband 9102 and the face mask assembly 9104, which remains intact throughout the process of putting on and taking off the patient interface 9100.

[0570] The closed-loop headband 9102 design can be formed through an internal molding (i.e., breakthrough) process in which the straps of the headband 9102 are formed from a textile shell filled with a plastic core. The textile shell provides a soft and comfortable contact surface for the straps, while the plastic core provides rigidity and structure, allowing the headband 9102 to maintain its shape.

[0571] Connector Overview

[0572] like Figure 95As shown, the upper strap 9108 and the lower strap 9110 are connected to the face mask assembly 9104 via connectors 9106 on each lateral side of the face mask assembly 9104. In some configurations, the straps 9108, 9110 may form part of the connector 9106. The connector 9106 is configured to act as a mechanism for securing the face mask assembly 9104 to the user's face while maintaining a closed loop between the face mask assembly 9104 and the headband 9102.

[0573] like Figure 97 and Figure 98 As shown, connector 9106 is configured to disengage from mask assembly 9104 (i.e., open or unlock) without damaging the closed loop between mask assembly 9104 and headband 9102, thereby increasing the effective length of the closed loop. Figure 97 A first perspective view is shown of the connector 9106 initially disengaged from the mask assembly 9104.

[0574] Figure 98 It shows Figure 97 A second perspective view of connector 9106, which is further disengaged from and extended from mask assembly 9104, demonstrates the effective increase in headband loop length achieved due to the disengagement of connector 9106. Preferably, the disengagement and extension of connector 9106 results in a minimum increase of 40 mm in headband loop length. This increase in headband loop allows the patient to easily put on and take off headband 9102. In some configurations, if headband 9102 has a degree of elasticity, the minimum increase in length may be less than 40 mm.

[0575] Therefore, the headband 9102, mask assembly 9104, and connector arrangement 9106 provide a closed-loop headband design that includes a symmetrical connection mechanism to the mask assembly 9104. In other words, throughout the process of putting on and taking off the patient interface 9100, the closed loop between the mask assembly 9104 and the headband 9102 remains intact. This improves the ease with which the mask 9104 is centered on the user's face, and the closed loop can be secured in place without shifting the mask 9104 by utilizing the interaction between the user and the headband 9102 and connector 9106. This closed-loop headband design requires an "over-the-head" approach to putting on the patient interface 9100, reducing the likelihood of the patient becoming confused or incorrectly putting on the interface 9100. In other words, the closed-loop headband design and connector arrangement allow the user to comfortably, efficiently, and intuitively put on and take off the patient interface headband 9102. In addition, the closed-loop headband design and connector arrangement ensure that the patient interface seal remains centered on the face when the headband 9102 is put on and taken off.

[0576] Plastic movable hinge

[0577] Figure 99A A plastic movable hinge connector 9106 is shown, comprising a face mask connector member 9112, a headband connector member 9114, a first face mask hinge 9116, a second face mask hinge 9118, a first connector hinge 9120, and a second connector hinge 9122. The connector 9106 can be in a closed position, in which the face mask connector member 9112 and the headband connector member 9114 are adjacent to (i.e., covering, folded over, etc.) or latched to the face mask assembly 9104; it can also be in an open position, in which these members are in an extended position. In some configurations, the connector 9106 is fastened and secured against the face mask assembly 9104 in the closed position, such that the connector 9106 does not move or rotate. An advantage of the plastic movable hinge connector 9106 is that the fastening system is self-positioning, making the system difficult to misuse.

[0578] The headband connector component 9114 is substantially U-shaped, with headband connection points 9124 located at each lateral end of the headband connector component 9114. The headband connector component 9114 is molded as a single part. The headband connector component 9114 can be made of a soft fabric cover 9114a having an internal molded plastic core 9114b (see example). Figure 101B Alternatively, the headband connector member 9114 may be made of a molded plastic part having a fabric layer on one side. In some configurations, the fabric layer may be located on the outer surface of the headband connector member 9114. In other configurations, the fabric layer may be located on the inner surface of the member 9114.

[0579] The face mask connector component 9112 is also made of plastic. In the illustrated embodiment, there are two separate face mask connector components 9112, with the first component displaced vertically from the second component. That is, the first face mask connector component 9112 can be positioned above the second face mask connector component 9112 relative to a vertical plane.

[0580] The face mask connector component 9112 is connected at one end to the face mask frame 9126 of the face mask assembly 9104. The face mask connector component 9112 is connected at the other end to the headband connector component 9114. The face mask connector component 9112 may be integrally formed with the headband connector component 9114, or it may be connected using other methods such as adhesive bonding, radio frequency welding, ultrasonic welding, overmolding, snap-fit ​​mechanism, mechanical stitching, etc. The face mask connector component 9112 may also be integrally formed with the frame 9126 of the face mask assembly 9104. Alternatively, the face mask connector component 9112 may be connected using other methods, such as those previously mentioned.

[0581] In the closed position, the connector 9106 shown is positioned to contact the frame 9126 of the face mask assembly 9104, as indicated by the arrow. A recessed channel 9128 is provided on the frame 9126 and has a shape and profile corresponding to the face mask connecting member 9112 and the headband connecting member 9114. In the closed position, the face mask connecting member 9112 and the headband connecting member 9114 mate into the recessed channel 9128. This reduces the profile of the connector 9106 on the frame 9126, as well as the overall profile of the face mask assembly 9104.

[0582] When connector 9106 is in the closed position, mask assembly 9104 is secured to the user's face. When in the closed position, the frictional engagement between connector 9106 and recessed channel 9128 serves to hold connector 9106 against frame 9126 and within recessed channel 9128. Alternatively, snap-fit ​​engagement, hooks and pin clips, magnets, Velcro connection systems, latching mechanisms, or any other connection system can be used.

[0583] In the open position, the connector 9106 shown rotates in the direction opposite to the indicated arrow. When open, the connector 9106 rotates about both the faceplate hinge 9118 and the connector hinge 9122. That is, the connector 9106 rotates away from the frame 9126 and the recessed channel 9128. In the illustrated embodiment, the faceplate hinge 9118 and the connector hinge 9122 are movable hinges (i.e., flexible, thin hinges made of the same material as the faceplate connector components). In some configurations, such as... Figure 99B As shown, the movable hinge can be made into a single-piece structure.

[0584] Figure 100 A top view of a type of movable hinge 9130 is shown, which can be incorporated into a mask connector member 9112. The movable hinge 9130 includes a reduced-thickness section about which the hinge 9130 provides rotation. Reducing the thickness of the indicated area increases local flexibility. This allows the reduced-thickness area to act as a hinge point, or "movable hinge" 9130. In some configurations, the movable hinge 9130 may have a constant thickness along its length while still possessing the flexibility to provide rotation.

[0585] Figure 101A An exploded view of the plastic movable hinge faceplate connector component arrangement 9106 is shown. The areas of the faceplate connector component 9112 capable of hinged action can have, for example... Figure 100The outline shown, or another outline that enables a movable hinge configuration. In this configuration, the face mask connector member 9112 includes a protrusion 9132 that engages with a corresponding hole 9134 in the headband connector member 9114 to mate the two components. Figure 101B As shown, the protrusion 9132 is integrally formed with the face mask connector member 9112. In some configurations, the protrusion 9132 may not be integrally formed with the connector member 9112. In other configurations, the headband connector member 9114 may include the protrusion 9132, and the face mask connector member 9112 may include a hole 9134. A similar connection mechanism may be used between the face mask connector member 9112 and the face mask assembly 9104, or different connection mechanisms may be used.

[0586] Figure 102A A movable hinge connector 9106 is shown, which has a single face shield hinge 9116, a single connector hinge 9122, a recessed channel 9128, and a recessed surface 9136. The recessed surface 9136 is configured to receive the face shield connector member 9112 when the connector 9106 is in the closed position, and the recessed channel 9128 is configured to receive the headband connector member 9114.

[0587] Figure 102B A cross-section is also shown, depicting the core 9114b of the headband connector member 9114 and the face shield connector member 9112. In this configuration, the headband connector member 9114 and the face shield connector member 9112 are formed from a single continuous molded plastic part 9114b. The face shield hinge spans the vertical length of the face shield connector member 9112, thereby providing a larger surface area on which the face shield hinge and face shield assembly 9104 are adjacent. Furthermore, the longer face shield connector member 9112 includes a connector hinge. Increasing the hinge length increases the durability of the connector 9106.

[0588] Hook and column retaining system

[0589] Figure 103A and Figure 103B A plastic movable hinge connector device 9106 with a hook and post retaining system 9140 is shown. Figure 103A and Figure 103BThe connector 9106 is held in a closed position by a hook and post retaining system 9140. An elevated post 9140a is integrally formed on the mask assembly 9104, and a corresponding hook 9140b is located on the mask connector member 9112. The hook 9140b closes the post 9140a in the closed position and holds the connector 9106 in the closed position via a snap-fit ​​or interference fit connection. In some embodiments, the elevated post 9140a is integrally formed on the mask connector member 9112, and the corresponding hook 9140b is located on the mask assembly 9104.

[0590] In other embodiments, Figures 103A to 103B The connector can be held in a closed position using a magnetic holding system. One or more magnets may be located on the connector 9106, and one or more ferrometallic structures may be located on the mask assembly 9104. The magnetic attraction between the magnets and the ferrometallic structures serves to hold the connector 9106 in the closed position.

[0591] Other configurations of connector 9106 may use press-fit, for example, including one or more mushroom-shaped protrusions on connector 9106 and corresponding recesses on mask assembly 9104. Figure 103B The mask hinge 9116 and connector hinge 9122 are enclosed in dashed boxes because they can be replaced by any of the aforementioned movable hinge designs. In other embodiments, the hook and post retaining system 9140 can be alternatively replaced by any other suitable method for holding the connector in the closed position.

[0592] Fabric movable hinge

[0593] Figure 104A and Figure 104B A fabric movable hinge connector arrangement 9142 is shown, wherein connector 9106 is primarily made of thick fabric, incorporating plastic supports for increased rigidity. Fabric movable hinge connector 9142 includes a face mask connector member 9112, a headband connector member 9114, two face mask hinges 9116, and a connector hinge 9122. Face mask connector member 9112 is substantially "U"-shaped, as is headband connector member 9114. Face mask connector member 9112 and headband connector member 9114 are made from the same continuous piece of fabric (i.e., this fabric consists of two "U" shapes joined at the bottom of the "U").

[0594] The "U"-shaped face mask connector component 9112 and the headband connector component 9114 each include plastic supports to increase their rigidity, but such plastic supports are absent near the connector hinge 9122, meaning that the natural flexibility of the fabric is sufficient to facilitate the hinge movement. The fabric movable hinge connector 9142 can be manufactured by at least one of the several embodiments, two of which are described below.

[0595] In a first embodiment, the fabric movable hinge connector 9142 comprises a single piece of fabric that incorporates the "U" shape of both the face mask connector member 9112 and the headband connector member 9114. The connector 9106 further includes a "U"-shaped plastic reinforcement for reinforcing the face mask connector member 9112 and another "U"-shaped plastic reinforcement for reinforcing the headband connector member 9114. A space exists between the two plastic reinforcements at the connector hinge 9122 to allow the movable hinge between the two connector members 9112 and 9114 to function. Furthermore, the plastic reinforcement of the face mask connector member 9112 does not extend to the face mask hinge 9116 to allow the fabric movable hinge between the face mask assembly 9104 and the face mask connector member 9112 to function.

[0596] In the second embodiment, the fabric movable hinge connector 9142 comprises two pieces of fabric, each piece of fabric joining the face mask connector member 9112 and the headband connector member 9114 in a "U" shape into a single piece. The two pieces of fabric are aligned such that two "U"-shaped plastic supports are sandwiched between the two fabric layers. The plastic supports are then sealed within the two pieces of fabric. The two fabrics can be joined using stitching, radio frequency welding, adhesive bonding, or any other associated connection mechanism. Similar to the first embodiment, the plastic supports provide rigidity to the "U" shape of the headband connector member 9114 and the face mask connector member 9112, while allowing the fabric to act as movable hinges at the face mask hinge 9116 and the connector hinge 9122.

[0597] It should be noted that a preferred embodiment of the fabric movable hinge connector 9142 includes two headband connection points 9124. In an alternative embodiment, a retaining member can connect the upper and lower arms of the headband connector member 9114, allowing for a different number of headband connection points.

[0598] Silicon hinge

[0599] Figures 105A to 107B A connector arrangement 9106 with silicon portions is shown. The face shield connector component 9112 is formed of silicon (or other soft polymers such as TPE, TPU, TPV, etc.), while the headband connector component 9114 is formed of a rigid polymer.

[0600] Figures 105A to 105B A silicon hinge is shown, wherein a first end of a mask connector member 9112 is pivotally connected to a mask assembly 9104 via a mask hinge 9116. A second end of the mask connector member 9112 is pivotally connected to a headband connector member 9114 via a connector hinge 9122. In the illustrated embodiment, the mask connector member 9112 rotates about a central pin connected to the mask assembly 9104, thereby forming the mask hinge 9116. Furthermore, the mask connector member 9112 rotates about a central pin on the connector hinge 9122 to which the headband connector member 9114 engages. This allows the connector 9106 to move within a wide range.

[0601] The configuration shown also includes a recessed center 9144 on the face shield connector member 9112. This is the region 9144 in which the thickness of the member 9112 is reduced. This region 9144 reduces the stiffness of the face shield connector member 9112, allowing it to bend to a greater extent than it might be without the recessed center 9144.

[0602] The illustrated face mask connector component 9112 is held in the closed position to the face mask assembly 9104 via a protrusion on the face mask that mates with a corresponding hole in the face mask connector component 9112. In other embodiments, the face mask connector component 9112 may include the protrusion, and the face mask assembly 9104 may include the corresponding hole. Further embodiments may include any suitable retention mechanism (magnetic retention mechanism, Velcro retention mechanism, etc.).

[0603] Figures 106A to 106B An alternative silicone hinge arrangement is demonstrated. Instead of using a pivot hinge as the mask hinge, the mask hinge point 9116 is fixed so that the silicone bends during the opening process, thus folding onto itself. Therefore, connector 9106 has a biasing force in the direction required to close connector 9106. This simplifies the process of securing the mask assembly 9104 to the user's face.

[0604] Figures 107A to 107B A face mask connector component 9112 with an alternative silicon hinge arrangement is shown. This configuration of the face mask connector component 9112 includes a first portion 9112a of a first thickness and a second portion 9112b of a second thickness. The thickness of the first portion 9112a is greater than the thickness of the second portion 9112b. The first portion 9112a includes arrangements for a face mask hinge 9118 and a connector hinge 9122. The second portion 9112b includes arrangements for the connector hinge 9122. The face mask hinge 9118 includes a post in a face mask assembly 9104 about which the face mask connector component 9112 rotates. The connector hinge 9122 rotates about the face mask hinge 9118 (similarly about the axis as indicated).

[0605] The first portion 9112a has a greater thickness than the second portion 9112b in order to minimize bending within the first portion 9112a when the connector 9106 is in the open position. The frame 9126 of the mask assembly 9104 includes a hole 9148 to accommodate the increased thickness of the portion 9112a.

[0606] The second portion 9112b has a reduced thickness to increase the allowable bending within it. Allowing bending within the second portion 9112b increases the resilience of the connector 9106 when a force greater than required is applied to the connector during the opening process. The second portion 9112b of the face shield connector assembly 9112 includes a retaining cavity 9150 configured to engage with a retaining protrusion 9152 on the face shield assembly 9104 when the connector 9106 is in the closed position.

[0607] The headband connector component 9114 is made of a rigid polymer. The central portion of the headband connector 9114 includes a cavity 9154, the size of which is determined to accommodate the face shield connector component 9114 when the connector 9106 is in the closed position. The cavity 9154 ensures that the profile of the connector 9106 is minimized.

[0608] The connector hinge 9122 is positioned relative to the face shield connector member 9112 and the headband connector member 9114 differently from the previously described connector arrangement. The connector hinge 9122 is offset from the ends of both the face shield connector member 9112 and the headband connector member 9114, as... Figure 107B As indicated by the dotted line. The advantage of biasing the hinge 9122 is that it creates a mechanical hard stop at the maximum extension of the connector 9106. This hard stop is a result of the front edge of the headband connector member 9114 striking or contacting the inner surface of the face mask connector member 9112. This hard stop is beneficial because it prevents the user from excessively rotating the headband connector member 9114 relative to the face mask connector member 9112 at the connector hinge 9122, thus preventing the connector 9106 from reversing. Furthermore, this hard stop serves to maintain a greater width of the connector when it is open. This improves the usability of the headband 9102 and face mask assembly 9104 during putting on and taking off, as it makes it easier to pass the headband 9102 over the user's ears.

[0609] In some configurations, the size of the face mask connector member 9112 can be determined such that an interference fit is formed between the face mask connector member 9112 and the central cavity 9154 of the headband connector member 9114 when the connector 9106 is in the closed position. This is achieved by determining that the size of the face mask connector member 9114 is slightly larger than the cavity 9154 of the headband connector member 9114. Since the face mask connector member 9112 is silicon (or another soft polymer), the interference fit is formed when the connector 9106 is closed, and the headband connector member 9114 is pressed against the face mask connector member 9112, thereby compressing the face mask connector member 9112. When the connector 9106 is in the closed position, this interference fit helps to stabilize the headband connector member 9114 in the vertical direction. In an alternative embodiment, the face mask connector member 9112 may be made of a rigid polymer.

[0610] headband connection

[0611] Figures 108A to 108C A headband connection arrangement for connecting connector 9106 to headband 9102 is shown. Each lateral end of connector 9106 includes a headband connection 9124. The headband connection 9124 is in the form of a ring-shaped rigid structure having holes configured to receive the straps of headband 9102. One or more straps of headband 9102 are designed to fold backward over themselves via headband connection 9124 and are secured in place by one of the methods disclosed below. Headband connection 9124 can be integrally formed with the internal molded core 9114b of connector 9106.

[0612] Headband fixing mechanism

[0613] Figures 109A to 109B A headband holding mechanism 9160 is shown for securing the lengths of the headbands 9108 and 9110. As shown, after the headband 9102 loops back to itself, the headband can be held in place at a fixed length using a hook-and-loop fastener arrangement 9160a, a push-in engagement arrangement 9160b, or a magnetic holding system 9160c. In some configurations, alternative fastening arrangements may be used.

[0614] Figures 110A to 110B A push-fit headband retaining mechanism 9162 for securing the lengths of straps 9108 and 9110 is shown. The push-fit components (e.g., protrusions 9162a and holes 9162b) have a lateral profile that is longer than the vertical profile.

[0615] Top centering clamp connector

[0616] Figures 111A to 111BAn alternative connector arrangement 9170 with an over-centering clamp design is demonstrated. The illustrated configuration uses a combination of pivots, hinges, and plastic components to achieve over-centering locking. Connector 9106 includes a face shield connector member 9112, a headband connector member 9114, a face shield hinge 9118, and a connector hinge 9122. This over-centering connector operates in a manner similar to a silicon hinge; however, the face shield connector member 9112 is rigid. The rigid member allows for a hard stop at the face shield hinge 9118, such as... Figure 111B As shown. The hard stop is used to maximize the rotation that the connector 9106 can undergo during operation. One advantage of doing so is that the position of the hard stop can be adjusted so that the connector 9106 maintains a greater width of the headband 9102 when in the open position, thereby allowing the headband 9102 to pass more easily through the ears when put on and taken off. The headband connector component 9114 includes two headband connection points 9124.

[0617] Extendable pivot connector

[0618] Figure 112A , Figure 112B and Figure 112C A connector configuration 9180 including an extendable pivot clamp is shown. The illustrated configuration includes a face mask connector member 9112 and a headband connector member 9114, which are coaxially aligned and configured such that the headband connector member 9114 is movable relative to the face mask connector member 9112 along their common axis. The face mask connector member 9112 projects perpendicularly to the face mask hinge 9118. In the closed position, the clamp holds the connector 9106 onto the face mask assembly 9104. To open the connector, the user applies a lateral force to the clamp on the face mask assembly to disengage it. The face mask connector member 9112 and the headband connector member 9114 are then rotated outward about the face mask hinge 9118. Figure 112B Once the pivot is opened, a telescopic movement can be made to pull the face mask connector component 9112 away from the face mask assembly 9104 outward, thereby extending the length of the connector 9106. Figure 112C In addition to increasing the length of the headband loops, this configuration also helps to keep the headband 9102 away from the user's ears, thus simplifying the removal process.

[0619] Sliding strap hard stop connector

[0620] Figure 113A and Figure 113BA connector configuration with a hard-stop sliding strap connector configuration 9190 is shown. In this configuration, the lateral portion of the headband 9102 contacts the user's cheek and engages with the connector 9106. The connector strap interface 9192 on the face mask assembly 9104 serves as the anchor point for the headband straps 9108, 9110. In the illustrated configuration, both headband straps 9108, 9110 engage with the connector 9106. The connection mechanism of each headband strap 9108, 9110 at the connector strap interface 9192 is unrestricted. That is, the connector configuration can include various types of connection mechanisms. In the illustrated configuration, the straps 9108, 9110 loop back onto themselves through an opening on the face mask assembly 9104. Once looped through the face mask assembly 9104, the straps 9108, 9110 can be securely attached to themselves (e.g., by stitching), or they can be attached to themselves via a hook-and-loop fastener connection system.

[0621] Each strap 9108, 9110 passes through a first reverse point 9193a located on the headband 9102. After passing through the first reverse point 9193a, the straps 9108, 9110 extend to a second reverse point 9193b, where they loop back onto themselves and are secured in place. In the illustrated configuration, the straps 9108, 9110 are secured to themselves after the second reverse point 9193b via a hook-and-loop fastener connection system. The securing system is not limited to a hook-and-loop fastener connection system, but may include other connection systems. Adjusting the strap length via the second reverse point 9193b is one way for the user to adjust the tightness of the headband 9102 in this configuration.

[0622] The second reverse point 9193b is located on the clamp 9194. The clamp 9194 acts as part of the retaining mechanism of the connector 9106. The retaining point 9196 is located on the face mask assembly 9104 and interacts with the clamp 9194 to retain the connector 9106. In the illustrated configuration, the retaining point 9196 protrudes from the face mask assembly 9104, and the clamp 9194 is positioned above the front of the retaining point 9196. Tension in the headband 9102 and the connector assembly 9106 is then used to pull the clamp 9194 against the retaining point, as... Figure 113A As shown. The retaining mechanism 9190, including the clamp 9194 and the retaining point 9196, is not specifically limited, but may include other retaining mechanisms. The retaining mechanism may be a hook and post connection mechanism, or any other mechanism.

[0623] Hard stop connector at the end of the strap

[0624] Figure 114A and Figure 114BA connector configuration with a sliding strap hard stop 9200 is shown. In this configuration, each headband strap 9108, 9110 loops itself through the connector strap interface 9192 and is then held in place by a retaining mechanism (e.g., a hook-and-loop fastener) on the end of the headband strap. However, the end 9202 of the headband strap has a larger profile than the holes through which each strap passes in the connector strap interface 9192. Thus, when released, the ends 9108, 9110 of the headband straps can extend the headband loop by retracting backward through the connector strap interface 9192 but cannot easily pass through the mask assembly 9104. This allows the user to remove the headband 9102 without breaking the headband / mask assembly loop. The upper strap 9108 and the lower strap 9110 can be connected to each other to allow simultaneous adjustment of both.

[0625] Disconnect the mating magnet and tether connector.

[0626] Figure 115A and Figure 115B A connector assembly 9210 is shown that includes two clamps 9212a, 9212b, a magnetic connection 9214, and a tether 9216. In the closed position as Figure 115A shown, the two components of the magnetic connection 9214 are in contact with each other, and the first clamp 9212a and the second clamp 9212b are secured to the mask assembly 9104. The first clamp 9212a and the second clamp 9212b can be attached to the mask assembly 9104 by using hook-and-post clamps, magnetic components, or any other relevant mechanism.

[0627] As Figure 115B shown, the position of the magnetic connection 9214 on the periauricular loop of the headband 9102 allows the user to unfasten the second clamp 9212b when they wish to remove the mask assembly 9104, thus disconnecting the magnetic connection. The included tether 9216 is fixed at each point of the magnetic connection 9214 at one of its ends, such that when the magnetic connection 9214 is disconnected, the tether 9216 acts as a bridging member to prevent the lower length of the headband 9102 from falling completely. In the case where the magnetic connection 9214 is disconnected, the length of the headband loop 9102 below the user's ears is longer, allowing the user to not need to readjust the headband 9102 after removing the headband 9102 and when they wish to use the mask assembly 9104 again next time. In some configurations, the tether 9216 may not be included between the magnetic connections 9214.

[0628] Disconnect the mating clamp and tether connector

[0629] Figure 116A and Figure 116BA connector assembly 9220 is shown, which combines a hook or clamp 9222, a post 9224, and a tether 9226 as illustrated. In the closed position, the hook 9222 is engaged with the post 9224 on the mask assembly 9104. In the open position, the user releases the hook or clamp 9222, which extends the headband loop. The tether 9226 acts as a bridge between the hook or clamp 9222 and the retaining member or post 9224 on the mask assembly 9104. This maintains the closed loop of the headband 9102 while extending the headband loop sufficiently to ensure the user feels comfortable when removing the headband 9102.

[0630] Clamps and continuous tether connectors

[0631] Figure 117A and Figure 117B A clamp and continuous tether connector 9230 are shown, which combines a hook or clamp 9232, a post 9234, and a continuous tether 9236, wherein the continuous tether connects both connectors 9230 to the mask assembly 9104. In this configuration, each of the two connectors 9230 is connected by a common tether 9236. The tether 9236 passes through a tether channel 9238 located on the mask assembly 9104. The tether 9236 is preferably made of an elastic material. In the closed position, the clamp 9232 is secured to the post 9234 of the mask assembly 9104. When the user wishes to open the connectors 9230, they release the clamp 9232 and pull it open. The tether 9236 maintains the closed loop of the headband 9102 while allowing the length of the headband loop to increase due to its elasticity. This allows the user to effectively remove the mask assembly 9104.

[0632] Figure 118A and Figure 118B An alternative clamp and continuous tether connector 9230 combining a first tether 9236a and a second tether 9236b are shown. The first tether 9236a is displaced relative to the second tether 9236b in the vertical direction. The first tether 9236a passes through a first tether channel 9238a. The second tether 9236b passes through a second tether channel 9238b. The tethers 9236a and 9236b can move substantially parallel to each other. The clamp 9232 operates similarly to the first embodiment. As a result of including the first tether 9236a and the second tether 9236b, the clamp 9232 has an increased tendency to automatically align during putting on and taking off. This is likely due to the increased elasticity caused by the two tethers 9236a and 9236b.

[0633] Clamps and rigid tether connectors

[0634] Figure 119A and Figure 119BA connector assembly 9230 is shown, which has a clamp 9232 and a pair of rigid tethers 9236 for holding each lateral headband strap. In this configuration, the connector 9230 includes the clamp and the rigid tether system. As with the previous connector 9230, the clamp 9232 is used to hold the headband 9102 to the mask assembly 9104 and can be a hook and a post. Furthermore, however, two rigid tethers 9236 are integrated into the mask assembly. During initial headband setup, the lateral headband straps 9108, 9110 are each fed through a sliding hole in the rigid tether 9236, such that when secured, the lateral headband straps 9108, 9110 can slide through the slider 9240 of the rigid tether 9236. When the connector 9230 is placed in the open position, the headband 9102 can slide through the rigid tether slider to increase the size of the headband loops. However, the slider 9240 limits the maximum extension of the headband loop by acting as a hard stop when it reaches the clamp 9232.

[0635] Hook and pin ring connector

[0636] Figure 120A and Figure 120B A connector assembly 9250 with hook and pin ring connectors is shown. The connector 9250 shown includes a fixed connector point 9252, a clamp 9254, and a material length 9256. The fixed connector point 9252 is located on the upper portion of the face mask assembly 9104. At this point, the material length 9256 passes through a ring; folds back onto itself, and is then adjusted and secured in place (e.g., using hook-and-pin fasteners or magnetic connections). The material length 9256 passes through a first eye ring 9258, at which point it is redirected to a second eye ring 9260. The end of the material length or fabric length 9256 includes a clamp 9254, which allows the end of the fabric length 9256 to be removably attached to the face mask assembly 9104.

[0637] To open connector 9250, clamp 9254 is disconnected from mask assembly 9104. In the illustrated embodiment, clamp 9254 is a hook and pin clamp. Clamp 9254 can alternatively be a magnetic configuration, a press-fit configuration, or another clamp configuration. Releasing clamp 9254 increases the length of the headband loop, thereby allowing the patient to put on and take off headband 9102, as shown. Clamp 9254 acts as a hard stop on the second eye loop 9260, which allows the maximum length of the headband loop to be i...

Claims

1. A headband for use with a breathing device, comprising: A first strap, the first strap including a first tubular textile outer shell; as well as A second strap, comprising a second tubular textile outer shell, is connected to the first strap at a location between the end portions of the first strap. The integral plastic core material is integrally formed within the textile outer shell of both the first and second straps, and The integral plastic core material penetrates the wall of the first tubular textile shell of the first strap and enters the open end of the second tubular textile shell of the second strap to connect the second strap to the first strap.

2. The headband according to claim 1, wherein, The integral plastic core material combines the first tubular textile shell of the first strap and the second tubular textile shell of the second strap.

3. The headband according to claim 1 or 2, further comprising a connector surrounding the connection between the first strap and the second strap.

4. The headband according to claim 3, wherein, The integral plastic core material is combined with the connector, so that the connector, the first tubular textile shell, the second tubular textile shell and the integral plastic core material are formed into an integral structure.

5. The headband according to claim 1, wherein, The first strap and the second strap are connected via a connecting member positioned between the first strap and the second strap, the connecting member being formed of the integral plastic core material.

6. The headband according to claim 5, wherein, The integral plastic core material is elastic, allowing the connecting components to be stretched.

7. The headband according to claim 1, wherein, The first and second straps are connected via an integrally formed fiber web portion, which is positioned between the first and second straps and is formed of an integral plastic core material.

8. The headband of claim 7 further comprises a soft-to-the-touch material covering the outer surface of the fiber web portion.

9. The headband according to any of the preceding claims, wherein the first tubular textile shell and the second tubular textile shell have a seamless tubular shape.

10. The headband according to any of the preceding claims, wherein the first tubular textile shell and the second tubular textile shell are knitted, woven, braided or crocheted.

11. The headband according to any of the preceding claims, wherein the end portion of the first tubular textile shell of the first strap abuts against the second tubular textile shell of the second strap.

12. The headband of claim 11, wherein the end portion of the first tubular textile outer shell of the first strap has a sealing portion.

13. The headband of claim 12, wherein the sealing portion is formed by cutting with a hot cutter.

14. The headband according to any of the preceding claims further includes a strap connector positioned on the outer surface of at least one of the first strap and the second strap, wherein the strap connector is formed from the integral plastic core material.

15. The headband according to any of the preceding claims, wherein at least one of the first strap and the second strap includes a soft edge portion extending along the edge of the first strap and / or the second strap in a longitudinal direction.

16. The headband of claim 15, wherein the soft edge portion of at least one of the first strap and the second strap includes the unfilled portion of the integral plastic core material of the first tubular textile shell of the first strap and / or the second tubular textile shell of the second strap.

17. A method for forming a headband within a molding tool, comprising: The first tubular textile shell and the second tubular textile shell are placed inside the cavity of the molding tool; Molten plastic material is introduced into the molding tool and then into the first tubular textile shell; The molten plastic material is pushed through the wall of the first tubular textile shell into the open end of the second tubular textile shell; as well as The molten plastic material is allowed to solidify within the first tubular textile shell and the second tubular textile shell to form a monolithic plastic core.

18. The method of forming a headband within a molding tool according to claim 17, wherein pushing the molten plastic material through the wall of the first tubular textile shell into the open end of the second tubular textile shell further comprises displacing a thread of the first tubular textile shell to form a gap in the wall of the first tubular textile shell, through which the molten plastic material flows into the second tubular textile shell.

19. The method of forming a headband within a molding tool according to claim 17, wherein pushing the molten plastic material through the wall of the first tubular textile shell into the open end of the second tubular textile shell further comprises linearly deforming the first tubular textile shell to form a gap in the wall of the first tubular textile shell, through which the molten plastic material flows into the second tubular textile shell.

20. The method of forming a headband within a molding tool according to claim 17, wherein pushing the molten plastic material through the wall of the first tubular textile shell into the open end of the second tubular textile shell further comprises tearing the thread of the first tubular textile shell to form a hole in the wall of the first tubular textile shell, through which the molten plastic material flows into the second tubular textile shell.

21. The method for forming a headband within a molding tool according to any one of claims 17 to 20, wherein placing a first tubular textile shell and a second tubular textile shell within the cavity of the molding tool further comprises positioning the first tubular textile shell in contact with the second tubular textile shell.

22. The method of forming a headband in a molding tool according to claim 21, wherein the end portion of the first tubular textile shell abuts against the second tubular textile shell at a position between the end portions of the second tubular textile shell.

23. The method of forming a headband within a molding tool according to claim 21, wherein the first tubular textile shell and the second tubular textile shell are in contact with each other at a location between their end portions.

24. The method for forming a headband within a molding tool according to any one of claims 17 to 23, wherein the outer edge of the cavity narrows relative to the central portion of the cavity, such that the outer edges of the first tubular textile shell and the second tubular textile shell are secured to prevent molten plastic material from flowing between the outer edges of the first tubular textile shell and the outer edges of the second tubular textile shell.

25. The method for forming a headband within a molding tool according to any one of claims 17 to 24, wherein the molten plastic material is pushed through the wall of the first tubular textile shell into the open end of the second tubular textile shell such that the first tubular textile shell and the second tubular textile shell are bonded together.

26. The method of forming a headband within a molding tool according to claim 17, further comprising positioning an end of a first tubular textile housing into a cavity of a tubular connector, and positioning a portion of a sidewall of a second tubular textile housing adjacent to or within the cavity of the tubular connector to push the molten plastic material through the wall of the first tubular textile housing and through the tubular connector into the open end of the second tubular textile housing.

27. The method of forming a headband in a molding tool according to claim 26, further comprising abutting the end of the first tubular textile shell against the second tubular textile shell.

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