Patient interface elbow assembly, anti-asphyxia valve for elbow assembly and connector

Abstract

The present disclosure relates to patient interface elbow assemblies, anti-asphyxia valves for elbow assemblies, and connectors. An interface for positive air pressure therapy is disclosed herein, the interface comprising a mask assembly, a headgear assembly, and a connection port assembly. The mask assembly comprises a sealing member having an upper portion movably connected to an integrated lower portion, wherein the upper portion rotates during hinged movement of the upper portion relative to the lower portion. The headgear assembly allows connection to the mask assembly in a direction substantially perpendicular to the direction of strap tensioning. The connection port assembly comprises a swivel elbow having a valve member that controls flow through a port opening towards the user. The valve member is provided with a tapered bead that helps prevent the valve member from sticking in a given position. Furthermore, a connector for connecting a breathing tube to an elbow connector is disclosed herein.

Description

[0001] This application is a divisional application of patent application 201680057234.7, filed on July 29, 2016, entitled "Patient Interface Bending Assembly, Anti-Suffocation Valve and Connector for Bending Assembly".

[0002] Citations of disclosed literature

[0003] This disclosure references features of the following patent applications: U.S. Patent Application No. 62 / 199,513, filed July 31, 2015; U.S. Patent Application No. 62 / 199,547, filed July 31, 2015; U.S. Patent Application No. 62 / 209,822, filed August 25, 2015; U.S. Patent Application No. 62 / 232,293, filed September 24, 2015; U.S. Patent Application No. 62 / 305,284, filed March 8, 2016; U.S. Patent Application No. 62 / 358,790, filed July 6, 2016; and U.S. Patent Application No. 62 / 360,052, filed July 8, 2016. The entire disclosure of these applications forms part of this specification, as if fully set forth herein, and is incorporated herein by reference in its entirety for all purposes. Technical Field

[0004] This invention generally relates to patient interfaces for respiratory therapy. More specifically, it relates to a bend assembly for a patient interface, such as a mask that covers at least one of a user's nose and mouth to supply breathing gas under positive pressure. More particularly, the invention relates to a bend assembly having an anti-asphyxiation valve (AA valve) arranged to allow the user to continue breathing if the supply of breathing gas is shut off or stopped for any reason. The invention also relates to a connector for connecting a catheter to a patient interface, such as via a bend assembly (preferably, the bend assembly disclosed herein). The invention further relates to a headgear for securing a breathing mask to a user's head. Background Technology

[0005] Many types of headgear exist for use with patient interfaces in respiratory therapy. However, because patient interfaces are frequently and / or worn over long periods in some applications (e.g., treatment of obstructive sleep apnea (OSA), continuous improvements are needed to enhance user convenience and comfort while maintaining or improving the interface's seal.

[0006] Face masks are used to provide breathing air to a user under positive pressure. In configurations that cover both the user's mouth and nose, a full-face mask typically rests on the bridge of the nose. Typically, a single seal will wrap around the user's nose and mouth.

[0007] These full-face masks are typically secured to the user's head with a headband. To minimize leakage, the headband is typically tightened, resulting in increased pressure on the user's nose. In other words, when the headband is tightened, the seal typically applies a progressively increasing load on the nose. Such masks typically feature a bend assembly comprising a tubular conduit extending at a 90-degree angle, one end of which is in fluid communication with the mask, and the other end connected to the breathing gas delivery tubing. The inability of the AA valve in this bend assembly to open or close fully or reliably can be a problem.

[0008] Numerous different breathing masks have been designed. Many of these masks are configured to provide a sealed connection to the user's airway by sealing the portion around the user's nose and / or mouth. These masks are commonly used to deliver treatments such as, but not limited to, noninvasive ventilation (NIV) and stable positive airway pressure (CPAP). CPAP therapy is commonly used to treat obstructive sleep apnea (OSA) and involves providing a constant supply of pressurized air to the user's airway. This opens the airway, thus minimizing airway collapse and reducing apnea. As part of this therapy, a deflection ventilation system is used to flush exhaled carbon dioxide (CO2) from inside the mask, which reduces or eliminates the possibility of re-inhalation.

[0009] Deflecting ventilation systems can be a identifiable source of noise. The draft can be bothersome to the user and / or their bed partner, potentially leading to decreased treatment compliance. Deflecting ventilation systems are also difficult to clean, which can result in contamination or further reduced treatment compliance. Such systems can also increase the volume of the breathing mask, further reducing user comfort when wearing it and thus decreasing the likelihood of user compliance.

[0010] Other common problems experienced with current headgear include the headgear being too heavy, bulky, and hot to wear, which can cause discomfort. Headgear made of traditional materials may dry slowly after washing. This can affect patients, as headgear often doesn't dry within a day, forcing them to either not wear their masks or wear them with wet headgear. This inconvenience associated with headgear cleaning may lead some patients to choose not to wash their headgear at all, which becomes unhygienic. Summary of the Invention

[0011] One object of this disclosure is to provide one or more constructions and / or methods that will at least partially improve the aforementioned problems or provide a useful option to the public or the medical industry. This disclosure also relates to a deflecting ventilation system for a respirator. Such a deflecting ventilation system is configured to diffuse exhausted air while improving ease of cleaning, reducing noise, and / or improving the compactness of the respirator. One object of this disclosure is to provide a respirator with a deflecting ventilation system that will at least provide a useful option to the public.

[0012] According to one aspect of the invention, a bend assembly is provided, the bend assembly being configured to connect a mask assembly to an air duct and / or other gas duct, the bend assembly including a bend and a sleeve, the bend including an inner wall and an outer wall defining an airflow passage therebetween, the inner wall including a port located on one side of the bend, the sleeve being coupled to the bend; the sleeve including a baffle, wherein when the baffle is in a first position, the baffle at least partially blocks the port and allows gas from the air duct to be delivered to the user via the bend, and when the baffle is in a second position, ... The baffle at least partially blocks the air duct, thereby allowing gas to flow from the user to a location outside the bend assembly via a port and an airflow channel, wherein the airflow channel directs air away from the side of the bend. The baffle includes an elongated beaded edge extending from the baffle and configured to contact the inner wall of the bend when the baffle is in a first position, thereby spaced the baffle from the inner wall of the bend. The beaded edge includes at least one tapered portion, which is configured such that when the baffle is viewed from the side, one portion of the beaded edge extends further from the baffle than another portion of the beaded edge.

[0013] In some embodiments, the bead rim extends around at least a portion of the periphery of the valve baffle.

[0014] In some embodiments, the bead rim extends around the entire periphery of the valve baffle.

[0015] In some embodiments, the baffle may include a hinge that pivotally mounts the baffle on a bend, with the bead edge extending around the periphery of the baffle to the hinge.

[0016] In some embodiments, the bead edge includes an arcuate bead edge portion away from the hinge, which is arcuate when the baffle is viewed in a plane.

[0017] In some embodiments, the bead edge includes at least one linear bead edge portion adjacent to the hinge, which is straight when the baffle is viewed in a plane.

[0018] In some embodiments, the at least one linear bead edge portion includes a sealing surface that is wider than the rest of the bead edge.

[0019] In some embodiments, when the baffle is in the first position, the width of the at least one linear beaded portion is substantially the same as the height of the surface of another portion of the bend assembly that the at least one linear beaded portion abuts against and seals thereto.

[0020] In some embodiments, a transition wall is defined between the at least one linear beaded portion and the remainder of the baffle, the transition wall extending from the edge of the linear beaded portion to the body of the baffle, the transition wall being configured to give the baffle structural rigidity.

[0021] In some embodiments, the transition wall is inclined relative to the plane of the valve baffle.

[0022] In some embodiments, when the baffle is viewed in a plane, the bead edge generally appears as an 'n' shape.

[0023] In some embodiments, when the baffle is viewed in a plane, the bead edge is generally 'D' shaped.

[0024] In some embodiments, the bead edge gradually tapers inward toward the valve baffle from a position away from the hinge to a position adjacent to the hinge; that is, the bead edge extends further from the baffle at a position away from the hinge.

[0025] In some embodiments, the bead edge tapers so that the bead edge is fused into the valve baffle at a location adjacent to the hinge.

[0026] In some embodiments, the bead edge includes: a top surface that contacts the inner wall of the bend when the baffle is in a first position; and an opposite side wall that extends between the valve baffle and the top surface, the top surface forming a sealing surface.

[0027] In some embodiments, at least one sidewall is curved.

[0028] In some embodiments, the shape of one sidewall is different from the shape of the other sidewall.

[0029] In some embodiments, the profile of a sidewall is such that the sidewall curves from the top surface into the plane of the valve baffle.

[0030] In some embodiments, at least one sidewall has a generally straight profile so that it extends in a straight line between the top surface and the valve baffle.

[0031] In some embodiments, the straight sidewalls are inclined relative to the plane of the valve baffle.

[0032] In some embodiments, the bead rim is integrally formed with the valve baffle.

[0033] In some embodiments, a plurality of beaded edges are provided.

[0034] In some embodiments, the bend assembly further includes an orientation feature arranged to facilitate mounting of supports and valve baffles in a desired orientation relative to the bend and sleeve.

[0035] In some embodiments, the orientation features include a slot on one of the support and the bend or sleeve and a protrusion on the other, the protrusion being received in the slot when the support and the valve baffle are mounted in the desired orientation.

[0036] In some embodiments, the airflow channel includes two airflow channels.

[0037] In some embodiments, the sleeve further includes a lug extending around the outer surface of the sleeve and a notch adjacent to the lug.

[0038] In some embodiments, the lug and recess are adapted to receive a rotating component, the rotating component including a ridge to engage with the lug.

[0039] In some embodiments, the sealing surface is generally straight when viewed from the side.

[0040] In some embodiments, the sealing surface includes a curved or inclined portion when viewed from the side.

[0041] In some embodiments, the baffle is configured such that, at least when the baffle is in the second position, the baffle is biased away from the bend and toward the sleeve.

[0042] In some embodiments, the baffle is configured such that, at least when the baffle is in the second position, the baffle deviates from the first position.

[0043] In some embodiments, the baffle is offset from the second position in a direction that is also away from the first position.

[0044] In some embodiments, the baffle includes a notch on the side of the baffle opposite to the bead edge.

[0045] In some embodiments, the notch is rectangular.

[0046] In some embodiments, the notch is adjacent to the hinge of the baffle.

[0047] In some embodiments, the bead edge may include an arcuate bead edge portion away from the hinge, which is arcuate when the baffle is viewed in a plane. The bead edge may additionally or alternatively include at least one linear bead edge portion adjacent to the hinge, which is straight when the baffle is viewed in a plane. In one example, the bead edge is generally 'n'-shaped when the baffle is viewed in a plane.

[0048] The bead edge can gradually taper inwards towards the valve baffle from a position away from the hinge to a position adjacent to the hinge; that is, the bead edge extends further from the baffle at the position away from the hinge. The bead edge can gradually taper so that it fuses into the valve baffle at the position adjacent to the hinge.

[0049] In some embodiments, the bead edge preferably includes: a top surface that contacts the inner wall of the bend when the baffle is in a first position; and opposing sidewalls that extend between the valve baffle and the top surface. At least one sidewall may be curved. At least one sidewall may be straight. The profile shape of one sidewall may differ from that of the other sidewall. In one example, the profile of one sidewall is such that the sidewall curves from the top surface into the plane of the valve baffle. In one example, the profile of at least one sidewall is generally straight so that the sidewall extends in a straight line between the top surface and the valve baffle. The straight sidewall may be inclined relative to the plane of the valve baffle.

[0050] In some embodiments, the beaded flange may be integrally formed with the valve baffle. Multiple beaded flanges may be provided.

[0051] In some embodiments, the baffle may include a baffle support mounted on at least one of the bend and the sleeve. Orientation features may be provided and arranged to facilitate mounting the support and valve baffle in a desired orientation relative to the bend and the sleeve. Orientation features may include a slot on one of the support and the bend or sleeve, and a protrusion on the other, the protrusion being received in the slot when the support and the valve baffle are mounted in the desired orientation.

[0052] In some embodiments, the flow channel may include two flow channels.

[0053] In some embodiments, the sleeve may further include a lug extending around the outer surface of the sleeve and a recess adjacent to the lug. The lug and recess may be adapted to receive a rotating component, the rotating component including a ridge to engage the lug.

[0054] According to another aspect of the invention, an anti-suffocation valve is provided for installation in a bend assembly, the bend assembly being configured to connect a mask assembly to an air conduit and / or other gas conduit, the bend assembly including a bend and a sleeve, the bend including an inner wall and an outer wall defining an air and / or other gas flow passage therebetween, the inner wall including a port located on one side of the bend, the sleeve being coupled to the bend; the valve including a support and a baffle pivotally mounted on the support, wherein when the valve baffle assembly is installed in the bend and the assembly and when the baffle is in a first position, the baffle at least partially blocks the port and allows gas to flow from the conduit. Gas is delivered to the user via the bend, and when the baffle is in the second position, the baffle at least partially obstructs the conduit, thereby allowing gas to flow from the user via a port and a flow channel to a location outside the bend assembly, wherein the flow channel directs air and / or other gases away from the side of the bend. The baffle includes an elongated beaded edge extending from the baffle and configured to contact the inner wall of the bend when the baffle is in the first position, so as to space the baffle from the inner wall of the bend. The beaded edge includes at least one tapered portion, which is configured such that, when viewed from the side, one portion of the beaded edge extends further from the baffle than another portion of the beaded edge.

[0055] In some embodiments, the elongated beaded edge extends around at least a portion of the periphery of the valve baffle.

[0056] In some embodiments, the elongated beaded edge extends around the entire periphery of the valve baffle.

[0057] In some embodiments, the valve baffle includes a hinge that pivotally connects the valve baffle to a conduit, the elongated beaded edge extending around the periphery of the baffle to the hinge.

[0058] In some embodiments, the elongated bead edge includes an arcuate bead edge portion away from the hinge, which is arcuate when the baffle is viewed in a plane.

[0059] In some embodiments, the elongated beaded edge includes at least one linear beaded edge portion adjacent to the hinge, which is straight when the baffle is viewed in a plane.

[0060] In some embodiments, the at least one linear beaded portion includes a sealing surface that is wider than the rest of the elongated beaded portion.

[0061] In some embodiments, when the baffle is in the first position, the width of the at least one linear beaded portion is substantially the same as the height of the surface of another portion of the conduit that the at least one linear beaded portion abuts against and seals.

[0062] In some embodiments, a transition wall is defined between the at least one linear beaded portion and the remainder of the valve baffle, the transition wall extending from the edge of the linear beaded portion to the body of the baffle, the transition wall being configured to give the baffle structural rigidity.

[0063] In some embodiments, the transition wall is inclined relative to the plane of the valve baffle.

[0064] In some embodiments, when the baffle is viewed in a plane, the elongated bead edge generally appears as an 'n' shape.

[0065] In some embodiments, when the baffle is viewed in a plane, the elongated bead edge is generally 'D' shaped.

[0066] According to another aspect, a connector is provided for directly or indirectly connecting an air conduit and / or other gas conduit to a patient interface, the connector including a first end and a second end; and a wall defining a gas path between the first end and the second end. The first end is configured to connect to a bend connector, while the second end is configured to connect to a breathing gas tube, including connection via a tube connector such as a collar terminating the breathing tube, and further wherein the second end of the connector is configured to prevent the second end of the connector from being fixedly attached to the bend connector.

[0067] Preferably, the second end of the connector is sized relative to the bend connector to provide the aforementioned protection. More specifically, according to a preferred embodiment, the engagement portion of the bend connector is configured to be received inside the connector, and the internal dimension of the second end is larger than the external dimension of the engagement portion of the bend connector.

[0068] Preferably, the connector is configured to be releasably and sealably secured to the bend connector via a snap-fit ​​or latching engagement. For this purpose, protrusions or recesses may be provided on the surface (preferably the inner surface) of the connector, and the mating portion of the bend connector may include corresponding recesses or protrusions. Therefore, the present invention can also provide a bend connector configured to engage novel and inventive connectors.

[0069] According to a preferred embodiment, the connector includes a protrusion on its outer surface, the protrusion being configured to act as a mechanical stop to limit the extent to which the breathing tube can be pushed onto the connector. The outer protrusion is preferably also configured to provide a grip for the user's fingers to aid in removing the connector from the bend connector. It should be noted that this outer protrusion can be used with or without a connector configured to prevent its second end from engaging with the mating portion of the bend connector (e.g., bend 29 or 29a).

[0070] According to another aspect, a connector is provided for directly or indirectly connecting an air tube and / or other gas tube to a patient interface, the connector including a first end and a second end; and a wall defining a gas path between the first end and the second end. The first end is configured to engage with a bend connector, while the second end is configured to engage with a breathing gas tube, and further wherein the connector includes a protrusion on its outer surface configured to act as a mechanical stop to limit the extent to which the breathing tube can be pushed onto the connector and / or to provide a gripper for the user's fingers to assist in removing the connector from the bend connector.

[0071] In some configurations, the bend connector is configured to connect to any of the connectors described above.

[0072] According to another aspect, an anti-asphyxiation valve for a breathing mask is provided, the anti-asphyxiation valve comprising: a conduit including a first end, a second end, and a port on one side of the conduit located between the first end and the second end, the first end being configured to receive an airflow from a gas source and the second end being coupled to the breathing mask; and a valve baffle assembly including a support and a valve baffle pivotally coupled to the support, wherein when the support of the valve baffle assembly is coupled to the conduit and when the valve baffle is in a first position, the valve baffle at least partially blocks the port and allows gas flow into the first end of the conduit. The valve baffle, when in the second position, at least partially blocks the first end of the catheter so that exhaled air entering the second end of the catheter flows through the port from the second end to a location outside the catheter. The valve baffle includes an elongated beaded edge extending from the valve baffle and configured to contact a portion of the inner wall of the catheter surrounding the port when the baffle is in the first position, thereby spaced the valve baffle from the inner wall of the catheter. The beaded edge includes at least one tapered portion configured such that, when viewed from the side, one portion of the beaded edge extends further from the baffle than another portion of the beaded edge.

[0073] In some embodiments, the elongated beaded edge extends around at least a portion of the periphery of the valve baffle.

[0074] In some embodiments, the elongated beaded edge extends around the entire periphery of the valve baffle.

[0075] In some embodiments, the baffle includes a hinge that pivotally connects the valve baffle to the conduit, the elongated beaded edge extending around the periphery of the baffle to the hinge.

[0076] In some embodiments, the elongated bead edge includes an arcuate bead edge portion away from the hinge, which is arcuate when the baffle is viewed in a plane.

[0077] In some embodiments, the elongated beaded edge includes at least one linear beaded edge portion adjacent to the hinge, which is straight when the baffle is viewed in a plane.

[0078] In some embodiments, the at least one linear beaded portion includes a sealing surface that is wider than the rest of the elongated beaded portion.

[0079] In some embodiments, when the baffle is in the first position, the width of the at least one linear beaded portion is substantially the same as the height of the surface of another portion of the conduit that the at least one linear beaded portion abuts against and seals.

[0080] In some embodiments, a transition wall is defined between the at least one linear beaded portion and the remainder of the valve baffle, the transition wall extending from the edge of the linear beaded portion to the body of the baffle, the transition wall being configured to give the baffle structural rigidity.

[0081] In some embodiments, the transition wall is inclined relative to the plane of the valve baffle.

[0082] In some embodiments, when the baffle is viewed in a plane, the elongated bead edge generally appears as an 'n' shape.

[0083] In some embodiments, when the baffle is viewed in a plane, the elongated bead edge is generally 'D' shaped.

[0084] In some embodiments, the elongated beaded edge gradually tapers inward toward the valve baffle from a position away from the hinge to a position adjacent to the hinge; that is, the elongated beaded edge extends further from the baffle at a position away from the hinge.

[0085] In some embodiments, the elongated bead edge gradually tapers so that the elongated bead edge is fused into the valve baffle at a location adjacent to the hinge.

[0086] In some embodiments, the elongated bead edge includes a top surface that contacts the inner wall of the curved conduit when the baffle is in a first position; and an opposite side wall that extends between the valve baffle and the top surface, the top surface forming a sealing surface.

[0087] In some embodiments, at least one sidewall is curved.

[0088] In some embodiments, the shape of one sidewall is different from the shape of the other sidewall.

[0089] In some embodiments, the profile of a sidewall is such that the sidewall curves from the top surface into the plane of the valve baffle.

[0090] In some embodiments, at least one sidewall has a generally straight profile so that it extends in a straight line between the top surface and the valve baffle.

[0091] In some embodiments, the straight sidewalls are inclined relative to the plane of the valve baffle.

[0092] In some embodiments, the elongated bead edge is integrally formed with the valve baffle.

[0093] In some embodiments, a plurality of beaded edges are provided.

[0094] In some embodiments, the baffle further includes a baffle support, which is mounted on at least one of the bend and the sleeve.

[0095] In some embodiments, the anti-suffocation valve further includes an orientation feature arranged to facilitate mounting of the support and valve baffle in a desired orientation relative to the bend and sleeve.

[0096] In some embodiments, the orientation features include a slot on one of the support and the bend or sleeve and a protrusion on the other, the protrusion being received in the slot when the support and the valve baffle are mounted in the desired orientation.

[0097] In some embodiments, the airflow channel includes two airflow channels.

[0098] In some embodiments, the sleeve further includes a lug extending around the outer surface of the sleeve and a notch adjacent to the lug.

[0099] In some embodiments, the lug and recess are adapted to receive a rotating component, the rotating component including a ridge to engage with the lug.

[0100] In some embodiments, the sealing surface is generally straight when viewed from the side.

[0101] In some embodiments, the sealing surface includes a curved or inclined portion when viewed from the side.

[0102] In some embodiments, the baffle is configured such that, at least when the baffle is in the second position, the baffle is biased away from the bend and toward the sleeve.

[0103] In some embodiments, the baffle is configured such that, at least when the baffle is in the second position, the baffle deviates from the first position.

[0104] In some embodiments, the baffle is offset from the second position in a direction that is also away from the first position.

[0105] In some embodiments, the baffle includes a notch on the side of the baffle opposite to the edge of the elongated bead.

[0106] In some embodiments, the notch is rectangular.

[0107] In some embodiments, the notch is adjacent to the hinge of the baffle.

[0108] It should be understood that while air can be provided as a respiratory aid, this can be supplemented or replaced by other gases. Alternatively, medications can be delivered to the patient, such as via a nebulizer connected to a patient interface, or more typically, by feeding gas into part of the patient's breathing circuit. Therefore, references to "air" or even "gas" should not be interpreted narrowly.

[0109] According to another aspect, a kit for a breathing mask is provided, the kit including a connecting shell placed on a patient's face during use. The connecting shell includes: a buffer end portion configured to engage a buffer shell for contact with a user's face; and a connecting ring opposite the buffer end portion. The connecting ring includes a first connecting shell protrusion and a second connecting shell protrusion, each generally arcuate and extending away from the buffer end portion and each including an array of at least one hole extending along at least a portion of the respective arcuate portion and configured to deliver exhaled gas from the user to the surrounding atmosphere during use, and the first and second connecting shell protrusions defining a generally arcuate first connecting shell recess and a generally arcuate second connecting shell recess between them, wherein the arc length of the first connecting shell recess is less than the arc length of the second connecting shell recess. The kit also includes an annular socket configured to deliver inhaled gas from a gas supply to the connecting shell. The socket includes a generally arcuate first socket protrusion and a generally arcuate second socket protrusion, wherein the arc length of the first socket protrusion is less than the arc length of the second socket protrusion, and the first and second socket protrusions define a generally arcuate first socket groove and a generally arcuate second socket groove therebetween. The socket is configured to removably engage with the connecting housing as an integral structure, such that, upon engagement, the first socket protrusion engages with a first connecting housing recess, the second socket protrusion engages with a second connecting housing recess, the first connecting housing protrusion passes through a frame opening and engages with the first socket groove, and the second connecting housing protrusion passes through a frame opening and engages with the second socket groove, thereby enabling, during use, inhaled gas to be delivered to the breathing mask and exhaled gas to be delivered from the breathing mask via the integral structure.

[0110] In some configurations, the rotary connector is configured to deliver inhaled gas to a user. The rotary connector includes a generally tubular first end and a truncated ball joint at a second end opposite to the first end, the truncation defining a ball joint opening configured to allow inhaled gas to pass through therethrough, wherein a socket is configured to receive the truncated ball joint in use.

[0111] In some configurations, the first bearing groove is the opposite of the second bearing groove.

[0112] In some configurations, the protrusion of the first connecting housing is opposite to the protrusion of the second connecting housing.

[0113] In some configurations, the frame is placed on a connecting housing during use. The frame includes a frame housing, which includes a frame opening and a support recess placed within the frame opening.

[0114] In some configurations, the frame shell is molded into the bearing housing.

[0115] In some configurations, the first connecting housing protrusion and the second connecting housing protrusion each include a generally L-shaped end portion in the region furthest from the buffer end portion, and the first socket protrusion and the second socket protrusion each include a generally L-shaped side portion in the region adjacent to the first socket groove and the second socket groove, and the generally L-shaped end portions of the first connecting housing protrusion and the second connecting housing protrusion are configured to seal with the generally L-shaped side portions of the first socket protrusion and the second socket protrusion.

[0116] In some configurations, the first connecting housing protrusion and the second connecting housing protrusion each include a generally straight end portion in the region furthest from the buffer end portion, and the first socket protrusion and the second socket protrusion each include a generally straight side portion in the region adjacent to the first socket groove and the second socket groove, and the generally straight end portions of the first connecting housing protrusion and the second connecting housing protrusion are configured to seal with the generally straight side portions of the first socket protrusion and the second socket protrusion.

[0117] According to another aspect, a kit for a breathing mask is provided, the kit including a connecting shell that is placed on a patient's face during use. The connecting shell includes: a buffer end portion configured to engage with the connecting shell for contact with a user's face; and a connecting ring opposite the buffer end portion. The connecting ring includes a first connecting shell protrusion and a second connecting shell protrusion, each generally arcuate and extending away from the buffer end portion and each including an array of at least one hole, the array of holes extending along at least a portion of the respective arcuate arc and configured to deliver exhaled gas from the user to the surrounding atmosphere during use, and the first and second connecting shell protrusions defining a generally arcuate first connecting shell recess and a generally arcuate second connecting shell recess between them, wherein the arc length of the first connecting shell recess is less than the arc length of the second connecting shell recess. The kit also includes: a frame that is placed on the connecting shell during use. The frame includes a frame housing, the frame housing including a frame opening defining a generally annular frame opening periphery, and an annular recess configured to deliver inhaled gas from a gas supply to a connecting housing. The recess within the frame housing is concentrically arranged with the frame opening and spaced from the periphery of the frame opening by a generally arcuate first frame protrusion and a generally arcuate second frame protrusion, wherein the arc length of the first frame protrusion is less than the arc length of the second frame protrusion, and the spacing between the recess and the periphery of the frame opening includes a first frame gap and a second frame gap. The frame is configured to removably engage with the connecting housing as an integral structure, such that, upon engagement, the first frame protrusion engages with a first connecting housing recess, the second frame protrusion engages with a second connecting housing recess, the first connecting housing protrusion passes through the frame opening and engages with the first frame gap, and the second connecting housing protrusion passes through the frame opening and engages with the second frame gap, thereby enabling the delivery of inhaled gas to a breathing mask and exhaled gas from the breathing mask via the integral structure during use.

[0118] In some configurations, a rotary connector is configured to deliver inhaled gas to a user. The rotary connector includes a generally tubular first end and a truncated ball joint at a second end opposite to the first end. The truncated ball joint defines an opening in the ball joint, which is configured to allow inhaled gas to pass through it. A socket is configured to receive the truncated ball joint in use.

[0119] In some configurations, the first bearing groove is the opposite of the second bearing groove.

[0120] In some configurations, the protrusion of the first connecting housing is opposite to the protrusion of the second connecting housing.

[0121] In some configurations, the frame shell is molded into the bearing housing.

[0122] In some configurations, the first connecting housing protrusion and the second connecting housing protrusion each include a generally L-shaped end portion in the region furthest from the buffer end portion, and the first socket protrusion and the second socket protrusion each include a generally L-shaped side portion in the region adjacent to the first socket groove and the second socket groove, and the generally L-shaped end portions of the first connecting housing protrusion and the second connecting housing protrusion are configured to seal with the generally L-shaped side portions of the first socket protrusion and the second socket protrusion.

[0123] In some configurations, the first connecting housing protrusion and the second connecting housing protrusion each include a generally straight end portion in the region furthest from the buffer end portion, and the first socket protrusion and the second socket protrusion each include a generally straight side portion in the region adjacent to the first socket groove and the second socket groove, and the generally straight end portions of the first connecting housing protrusion and the second connecting housing protrusion are configured to seal with the generally straight side portions of the first socket protrusion and the second socket protrusion.

[0124] According to another aspect, a kit for a breathing mask is provided, the kit comprising: a rotary connector configured to deliver inhaled gas to a user, the rotary connector including a generally tubular first end and a truncated ball joint located at a second end opposite to the first end, the truncated portion defining a ball joint opening configured to allow inhaled gas to pass through therethrough; and a connecting housing placed on the user's face during use. The connecting housing includes: a connecting housing opening configured to receive inhaled gas from the rotary connector and exhaled gas exhaled by the user during use; and a buffer end portion opposite to the connecting housing opening and configured to engage with a buffer housing for contact with the user's face. The kit further includes a hollow socket including a closed internal region. The closed internal region includes a connecting housing engagement region generally circumferentially surrounding a first end of the socket, the connecting housing engagement region engaging with the connecting housing opening during use and configured to receive exhaled gas therefrom. The connecting housing engagement region includes: a first diameter; a spherical connector engagement region generally circumferentially surrounding a second end of a socket opposite to the first end, the spherical connector engagement region engaging with a truncated spherical connector of a rotary connector in use and configured to receive inhaled gas therefrom, the spherical connector engagement region including a second diameter smaller than the first diameter; a generally arcuate first bearing region and a generally arcuate second bearing region, each extending from the spherical connector engagement region toward the connecting housing engagement region and each engaging with a truncated spherical connector of a rotary connector in use, the first bearing region and the second bearing region defining a generally arcuate first exhalation region and a generally arcuate second exhalation region therebetween; a third diameter between the first exhalation region and the second exhalation region, the third diameter being larger than the second diameter and smaller than or equal to the first diameter, and each of the first exhalation region and the second exhalation region including an array of at least one hole, the array of at least one hole being configured to allow exhaled gas to pass through it and be delivered to the ambient atmosphere outside the socket. The arc lengths of the first and second exhalation regions are greater than the arc lengths of the first and second support regions, and the frame is configured such that, during use, inhaled gas is transferred to the breathing mask via the support and exhaled gas is transferred from the breathing mask to the surrounding atmosphere.

[0125] In some configurations, the frame is placed on a connecting housing during use. The frame includes a frame housing, which includes a frame opening defining a generally annular frame opening periphery and a support recess placed within the frame opening.

[0126] In some configurations, the frame shell is molded into the bearing housing.

[0127] In some configurations, the interior of a certain length of the rotary connector has a continuous cylindrical or continuously tapering cylindrical profile, the certain length of which includes a second end, the entire truncated ball joint, and a region extending toward the first end directly adjacent to the truncated ball joint.

[0128] In some configurations, the internal profile of a truncated ball joint typically follows the corresponding external profile of the truncated ball joint.

[0129] In some configurations, the rotary connector and the socket are configured such that when the truncated ball joint of the rotary connector is rotated to its maximum extent in any direction within the ball joint engagement area of ​​the socket, the second end of the rotary connector is completely suspended above the ball joint engagement area within the socket.

[0130] In some configurations, the rotary connector and the socket are configured such that when the truncated ball joint of the rotary connector is in the middle of the ball joint engagement area of ​​the socket, the second end of the rotary connector is completely suspended over the first and second bearing areas within the socket.

[0131] In some configurations, the outer profile of the spherical joint junction region facing the surrounding atmosphere has a continuous slope.

[0132] In some configurations, the outer contour of the spherical joint engagement region facing the surrounding atmosphere has a first slope with respect to the distance from the second end to a certain point, and a second slope with respect to the remaining length of the spherical joint engagement region extending from said point toward the first end, the second slope being different from the first slope.

[0133] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a buffer housing; a frame having an opening and an inner wall defining the opening; a rotating bend configured to provide inhaled gas from a gas supply, the rotating bend having a ball joint; and an annular insert disposed within the opening of the frame. The annular insert includes: a cover portion; a collar portion extending peripherally away from the cover portion in a direction toward the user during use; an inner region defined by the cover portion and the collar portion, the inner region being configured to pass inhaled gas from the gas supply to a connecting housing and receive exhaled gas exhaled by the user; a rotating bend socket extending through the cover portion and configured to engage with the ball joint; and a ventilation region disposed on the cover portion and positioned on a lateral side of the rotating bend socket, the ventilation region having a vent extending through the cover portion to pass exhaled gas received by the inner region into the ambient atmosphere during use. The collar portion engages with the inner wall of the opening, such that the vent insert is placed within the opening and connected to the frame, and the collar portion engages with the buffer housing, such that the buffer housing is attached to the frame via the vent insert.

[0134] In some configurations, the rotary bend socket also includes a lateral socket sidewall configured to engage with a spherical connector, the inner surface of which extends away from the cap portion into the inner region of the annular insert. The central portion of the lateral socket sidewall extends a greater distance into the inner region of the annular insert compared to the end portions of the lateral socket sidewall.

[0135] In some configurations, the rotary bend socket also includes a lower socket sidewall configured to engage with the lower portion of the ball joint, the inner surface of which extends away from the cap portion into the inner region of the annular insert. The end portions of the lower socket sidewall and the end portions of the lateral sidewall extend equidistantly into the inner region of the annular insert.

[0136] In some configurations, the rotary bend socket also includes an upper socket sidewall configured to engage with the upper portion of the ball joint, the inner surface of which extends away from the cap portion into the inner region of the annular insert. The end portions of the upper socket sidewall and the end portions of the lateral sidewall extend equidistantly into the inner region of the annular insert.

[0137] In some configurations, the end portions of the lateral sidewalls are integrally molded with the inner surface of the collar portion.

[0138] In some configurations, the collar portion is welded along the weld area to the inner wall of the frame opening.

[0139] In some configurations, each ventilation zone exhales the exhaled gas in a different inhalation direction.

[0140] In some configurations, the vent has a planar shape.

[0141] In some configurations, the annular insert also includes a recessed portion disposed between the bottom of the ball joint and the collar portion, wherein the recessed portion is configured to provide a shallow, user-accessible cavity to remove dirt build-up in the internal area.

[0142] In some configurations, the ball joint has a cut-off area on the bottom of the ball joint that engages with the recessed portion.

[0143] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a frame; a buffer housing; a rotating bend configured to provide inhaled gas from a gas supply, the rotating bend having a ball joint; and an annular socket attached to the frame. The annular socket includes: a cover portion; a collar portion extending in use toward a user away from an inner surface of the cover portion, the collar portion being connected to the buffer housing such that the buffer housing is attached to the frame; an inner region defined by the cover portion and the collar portion, the inner region being configured to deliver inhaled gas from the gas supply to a connecting housing and receive exhaled gas exhaled by the user; and a rotating bend socket extending through the cover portion and configured to engage with the ball joint, the rotating bend socket including a lateral socket sidewall configured to engage with the ball joint, the lateral socket sidewall extending away from the inner surface of the cover portion into the inner region of the annular socket, wherein a central portion of the lateral socket sidewall extends a greater distance into the inner region of the annular socket than an end portion of the lateral socket sidewall.

[0144] In some configurations, the rotary bend socket also includes a lower socket sidewall configured to engage with the lower portion of the ball joint, the inner surface of which extends away from the cap portion into the inner region of the annular socket. The end portions of the lower socket sidewall and the end portions of the lateral sidewall extend equidistantly into the inner region of the annular socket.

[0145] In some configurations, the rotary bend socket also includes an upper socket sidewall configured to engage with the upper portion of the ball joint, the inner surface of which extends away from the cap portion into the inner region of the annular socket. The end portions of the upper socket sidewall and the end portions of the lateral sidewall extend equidistantly into the inner region of the annular socket.

[0146] In some configurations, the end portions of the lateral sidewalls are integrally molded with the inner surface of the collar portion.

[0147] In some configurations, the annular socket also includes a recessed portion disposed between the bottom of the ball joint and the collar portion. The recessed portion is configured to provide a shallow, user-accessible cavity for removing dirt buildup within the internal area.

[0148] In some configurations, the ball joint has a cut-off area on the bottom of the ball joint that engages with the recessed portion.

[0149] In some configurations, the annular socket is configured to be inserted into and removably fastened to the frame.

[0150] In some configurations, the annular cavity also includes at least one ventilation area having a vent that extends through the cover portion to transfer exhaled air received by the internal area into the surrounding atmosphere during use.

[0151] In some configurations, each ventilation zone exhales the exhaled gas in a different inhalation direction.

[0152] In some configurations, the vent has a planar shape.

[0153] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a frame; a liner; a connecting housing having the liner connected to a first end; and a connecting ring attached to a second end of the connecting housing opposite to the first end. The connecting ring includes: a central opening extending through the connecting ring; and at least one protrusion extending in a direction away from the connecting housing and defining a portion of the central opening, the at least one protrusion including an array of at least one hole. The breathing mask assembly further includes an annular recess attached to the frame. The annular recess includes: a tubular central portion extending through the frame and a gas supply; and at least one slot extending through the annular recess and disposed adjacent to the tubular central portion, such that a portion of the at least one slot is defined by the outer surface of the tubular central portion. A connecting ring is configured to be removably disposed on the outer surface of a tubular central portion such that the tubular central portion extends through a central opening of the connecting ring, and at least one protrusion is configured to be inserted into the at least one slot such that the at least one protrusion extends through an annular socket, wherein the inner surface of the tubular socket defines a flow path to the liner for inhaled gas from a gas supply, and the outer surface of the tubular socket defines a flow path from the liner to an array of at least one orifice for exhaled gas to be released into the atmosphere.

[0154] In some configurations, a rotary connector is configured to deliver inhaled gas to a user, the rotary connector including a generally tubular first end and a truncated ball joint at a second end opposite to the first end, the truncation defining a ball joint opening configured to allow inhaled gas to pass through therethrough, wherein the tubular central portion is configured to receive the truncated ball joint in use.

[0155] In some configurations, the at least one slot further includes a first recessed groove and a second recessed groove opposite to the first recessed groove, and the at least one protruding portion further includes a first protruding portion and a second protruding portion opposite to the first protruding portion.

[0156] In some configurations, the annular bearing socket and the frame are formed integrally.

[0157] In some configurations, the annular socket is configured to be inserted into and removably fastened to the frame.

[0158] In some configurations, the annular socket further includes an L-shaped end portion disposed at the end of the tubular central portion opposite to the gasket; and the connecting ring further includes an L-shaped side portion disposed at the end of the at least one protruding portion opposite to the gasket, wherein the L-shaped end portion engages with the L-shaped side portion to form a seal between the annular socket and the connecting ring.

[0159] In some configurations, the annular socket further includes a straight end portion disposed at the end of the tubular central portion opposite to the gasket; and the connecting ring further includes a straight side portion disposed at the end of the at least one protruding portion opposite to the gasket, wherein the straight end portion engages with the straight side portion to form a seal between the annular socket and the connecting ring.

[0160] In some configurations, the breathing mask assembly includes: a frame; a liner; a connecting housing attached to the liner at a first end opposite to the second end; a rotary connector configured to provide inhaled gas from a gas supply, the rotary connector having a truncated ball joint; and an annular socket attached to the frame and to the second end of the connecting housing. The annular socket includes: a connecting housing engagement region configured to engage with the connecting housing; a ball joint engagement region configured to engage with the truncated ball joint of the rotary connector; and at least one ventilation region disposed between the connecting housing engagement region and the ball joint engagement region, the at least one ventilation region having an array of at least one orifice extending through the at least one ventilation region and configured to allow exhaled gas to pass through therethrough to be delivered into the surrounding atmosphere outside the annular socket. The inner surface of the truncated ball joint defines a flow path to the liner for inhaled gas from the gas supply, and the outer surface of the truncated ball joint defines a flow path from the liner to the array of at least one orifice for exhaled gas to be released into the atmosphere.

[0161] In some configurations, the annular bearing socket and the frame are formed integrally.

[0162] In some configurations, the annular socket is configured to be inserted into and removably fastened to the frame.

[0163] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint rotates to its maximum extent in any direction within the ball joint engagement area, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0164] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint is in the middle position within the ball joint engagement area of ​​the annular socket, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0165] In some configurations, the annular socket further includes a first bearing region and a second bearing region that engage with opposite sides of the truncated spherical joint, wherein the first bearing region and the second bearing region extend from the spherical joint engagement region in a direction toward the gasket, such that a recessed region is formed between the first bearing region and the second bearing region.

[0166] In some configurations, the ventilation area is located within a recessed area.

[0167] In some configurations, the flow path to the ventilation area is defined by the first and second bearing areas, the inner surface of the annular socket, and the outer surface of the truncated spherical joint.

[0168] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly including a liner, the liner including a connecting ring and a frame. The connecting ring includes: an opening; and at least one protrusion extending in a direction remote from the liner and defining a portion of the opening, the at least one protrusion including at least one exhaust port. The frame includes: a central conduit extending through the frame and configured to receive inhaled gas from a gas supply; at least one slot extending through the frame; and an annular collar extending from a patient-facing side of the frame and surrounding the central conduit and the at least one slot. The connecting ring is configured to be removably attached to the annular collar, and the at least one protrusion is configured to extend into the at least one slot. When attached, the at least one protrusion and the central conduit at least partially define a flow path from the liner to the at least one exhaust port for exhaled gas to be released into the atmosphere.

[0169] In some configurations, the at least one slot is positioned adjacent to the central conduit.

[0170] In some configurations, the gasket also includes a connecting housing disposed between the gasket and the connecting ring, such that the gasket is attached to the first end and the connecting ring is attached to the second end.

[0171] In some configurations, at least a portion of the slot is defined by the outer surface of the central conduit.

[0172] In some configurations, when attached, the central conduit at least partially defines the flow path to the liner for the inhaled gas from the gas supply.

[0173] In some configurations, a rotary connector is also included, which is configured to deliver inhaled gas to a user. The rotary connector includes a generally tubular first end and a truncated ball joint at a second end opposite to the first end. The truncation defines an opening in the ball joint, which is configured to allow inhaled gas to pass through it. The central conduit is configured to receive the truncated ball joint in use.

[0174] In some configurations, the at least one slot further includes a first recessed groove and a second recessed groove opposite to the first recessed groove, and the at least one protruding portion further includes a first protruding portion and a second protruding portion opposite to the first protruding portion.

[0175] In some configurations, the ring and the frame are formed integrally.

[0176] In some configurations, the annular collar is configured to insert and removably fasten to the frame.

[0177] In some configurations, the central conduit further includes an L-shaped end portion disposed at the end of the tubular central portion opposite to the gasket. The connecting ring also includes an L-shaped side portion disposed at the end of the at least one protruding portion opposite to the gasket. The L-shaped end portion engages with the L-shaped side portion to form a seal between the central conduit and the connecting ring.

[0178] In some configurations, the central conduit further includes a straight end portion disposed on the end opposite to the liner; and the connecting ring further includes a straight side portion disposed on the end of the at least one protruding portion opposite to the liner, wherein the straight end portion engages with the straight side portion to form a seal between the central conduit and the connecting ring.

[0179] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a frame; a liner; a connecting housing attached to the liner at a first end opposite to a second end; a rotary connector configured to provide inhaled gas from a gas supply, the rotary connector having a truncated ball joint; and an annular socket attached to the frame and to a second end of the connecting housing. The annular socket includes: a connecting housing engagement region configured to engage with the connecting housing; a ball joint engagement region configured to engage with the truncated ball joint of the rotary connector; and at least one ventilation region disposed between the connecting housing engagement region and the ball joint engagement region, the at least one ventilation region having an array of at least one orifice extending through the at least one ventilation region and configured to allow exhaled gas to pass through therethrough and be delivered to the surrounding atmosphere outside the annular socket. The inner surface of the truncated ball joint defines a flow path to the liner for inhaled gas from the gas supply. The outer surface of the truncated ball joint defines a flow path from the liner to the array of at least one orifice for exhaled gas to be released into the atmosphere.

[0180] In some configurations, the annular bearing socket and the frame are formed integrally.

[0181] In some configurations, the annular socket is configured to be inserted into and removably fastened to the frame.

[0182] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint rotates to its maximum extent in any direction within the ball joint engagement area, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0183] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint is in the middle position within the ball joint engagement area of ​​the annular socket, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0184] In some configurations, the annular socket further includes a first bearing region and a second bearing region that engage with opposite sides of the truncated spherical joint, wherein the first bearing region and the second bearing region extend from the spherical joint engagement region in a direction toward the gasket, such that a recessed region is formed between the first bearing region and the second bearing region.

[0185] In some configurations, the ventilation area is located within a recessed area.

[0186] In some configurations, the flow path to the ventilation area is defined by the first and second bearing areas, the inner surface of the annular socket, and the outer surface of the truncated spherical joint.

[0187] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a frame; a pad; a rotary connector having a first end configured to receive inhaled gas from a gas supply, and a second end; and an annular recess attached to the frame. The annular recess includes: a pad engagement region configured to engage with the pad; a rotary connector engagement region configured to engage with the second end of the rotary connector and including a first support region, a second support region, and a recessed region formed between the first support region and the second support region; and at least one ventilation region disposed between the pad engagement region and the rotary connector engagement region, wherein the at least one ventilation region is adjacent to the recessed region.

[0188] According to another aspect, a breathing mask assembly is provided, the breathing mask assembly comprising: a frame; a pad; a rotary connector having a first end configured to receive inhaled gas from a gas supply, and a second end; and an annular recess attached to the frame. The annular recess includes: a pad engagement region configured to engage with the pad; a rotary connector engagement region configured to engage with the second end of the rotary connector and including a first support region, a second support region, and a recessed region formed between the first support region and the second support region; and at least one ventilation region disposed between the pad engagement region and the rotary connector engagement region, wherein the at least one ventilation region is adjacent to the recessed region.

[0189] In some configurations, the inner surface of the rotary connector defines an intake flow path for the intake gas from the gas supply to the gasket.

[0190] In some configurations, the rotary connector is a truncated ball joint.

[0191] In some configurations, the outer surface of the rotary connector at least partially defines an exhalation flow path from the liner to at least one array of holes for the release of exhaled gases into the atmosphere.

[0192] In some configurations, at least one ventilation area further includes an array of at least one hole extending through the at least one ventilation area and configured to allow exhaled gas to pass through it and be delivered to the surrounding atmosphere outside the annular cavity.

[0193] In some configurations, the annular bearing socket and the frame are formed integrally.

[0194] In some configurations, the annular socket is configured to be inserted into and removably fastened to the frame.

[0195] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint rotates to its maximum extent in any direction within the ball joint engagement area, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0196] In some configurations, the rotary connector and the annular socket are configured such that when the truncated ball joint is in the middle position within the ball joint engagement area of ​​the annular socket, the open end of the truncated ball joint is completely suspended above the ball joint engagement area within the annular socket.

[0197] In some configurations, the annular socket further includes a first bearing region and a second bearing region that engage with opposite sides of the truncated spherical joint, wherein the first bearing region and the second bearing region extend from the spherical joint engagement region in a direction toward the gasket, such that a recessed region is formed between the first bearing region and the second bearing region.

[0198] In some configurations, the ventilation area is located within a recessed area.

[0199] In some configurations, the flow path to the ventilation area is defined by the first and second bearing areas, the inner surface of the annular socket, and the outer surface of the truncated spherical joint.

[0200] One or more embodiments relate to a headgear structure having at least a plurality of sections made of three-dimensional (3D) spaced fabric.

[0201] In a first aspect, this disclosure relates to a headgear for use with a breathing mask, the headgear comprising a component formed of two layers of 3D fabric, the two layers of 3D fabric being folded from 3D fabric sheets or tubes to have folded edges forming the edges of the headgear.

[0202] In some embodiments, the component is a rear panel, and the headgear includes a lower strap and an upper strap extending from the rear panel to connect to the face mask, the fold forming the edge of the rear panel.

[0203] In some embodiments, the folded edge forms the bottom edge of the rear panel.

[0204] In some embodiments, the bottom edge of the rear panel extends across the back of the user's neck during use.

[0205] In some embodiments, the two layers of 3D fabric are joined together by gluing, sewing or welding at other edges of the component.

[0206] In some embodiments, the two layers of 3D fabric are sewn together at the edges to form a seam edge that forms the edge of the headgear.

[0207] In some embodiments, the seam edge is located at the edge of the component opposite to the folded edge of the component.

[0208] In some embodiments, the fold is a first fold and the 3D fabric includes a second fold at the edge of the component opposite to the first fold.

[0209] In some embodiments, the fold is a first fold and the 3D fabric includes a second fold at the edge of the component opposite to the first fold, and a joint in one of the two layers of 3D fabric.

[0210] In some embodiments, the joint is in the outer layer of the 3D fabric.

[0211] In some embodiments, the joint is a welded joint.

[0212] In some embodiments, the two layers of 3D fabric are joined together by gluing, sewing, or welding at all other edges of the component.

[0213] In some embodiments, the 3D fabric has a front and a back side, and is folded such that the back side of the fabric is inside the component, while the front side of the fabric is outside the component.

[0214] In some embodiments, the back panel includes a peripheral portion formed of a material suitable for headwear, such as foam or fabric, to which one or more edges of the two layers of 3D fabric are attached.

[0215] In some embodiments, the peripheral portion extends from one end of the folded edge around the two layers of 3D fabric to the other end of the folded edge.

[0216] In some embodiments, the rear panel includes the peripheral portion along each lateral edge of the rear panel.

[0217] In some embodiments, the material of the peripheral portion extends into the strap of the headgear and forms at least a portion thereof.

[0218] In some embodiments, one or more edges of the two layers of 3D fabric, other than the folded edge, are attached to the peripheral portion by adhesive, stitching, or welding.

[0219] In some embodiments, the two layers of 3D fabric are welded or bonded together to the peripheral portion along each lateral edge of the two layers of 3D fabric.

[0220] In some embodiments, the folded edge is curved.

[0221] In some embodiments, 3D fabric wraps around or covers another part of the headgear.

[0222] In some embodiments, the headgear includes a back panel formed of a material suitable for the headgear (such as foam or fabric), and the material is wrapped or covered by 3D fabric.

[0223] In some embodiments, the 3D fabric has folds at the upper and lower edges of the back panel, and a joint in one layer of the two 3D fabrics.

[0224] In some embodiments, the joint is in the outer layer of the two 3D fabric layers.

[0225] In some embodiments, the joint is a welded joint.

[0226] In some embodiments, the joints in the 3D fabric layer bond the 3D fabric to the material beneath the 3D fabric layer.

[0227] In some embodiments, the headgear includes a non-adhesive or non-welding material or membrane between a material beneath the 3D fabric and one or two layers of 3D fabric, the non-adhesive or non-welding membrane or material preventing one or two layers of 3D fabric from attaching to the underlying material of the headgear.

[0228] In some embodiments, the headgear includes a non-adhesive or non-welding material or membrane between the base material and the inner layer of the 3D fabric, the non-adhesive or non-welding material or membrane preventing the joints in the outer layer of the 3D fabric from joining the base material and the inner layer of the 3D fabric.

[0229] In some embodiments, the component is a strap of a headgear, such as a lower strap, an upper strap, or a top strap.

[0230] In some embodiments, the joint between multiple layers of 3D fabric or within a single layer of 3D fabric is made such that the reverse side of the fabric is turned outwards, and then the right side of the fabric is turned outwards, so that the joint is located inside the two layers of 3D fabric.

[0231] In some embodiments, one or more edges of the two layers of 3D fabric, excluding the hem, are welded to a portion of the headgear, wherein one layer of the two layers of 3D fabric overlaps with the edge of the other layer of the two layers of 3D fabric, such that the weld includes a first region formed by the two layers of the two layers of 3D fabric and the portion of the headgear, and a second region formed by one layer of the two layers of 3D fabric and the portion of the headgear.

[0232] In some embodiments, the component is a back panel, the headgear includes a lower strap and an upper strap extending from the back panel to connect to the face mask, the fold forming an edge of the back panel, and wherein the portion of the headgear is a peripheral portion of the back panel formed of a material suitable for the headgear (such as foam or fabric).

[0233] In some embodiments, in the weld, the inner layer of the two 3D fabrics is located between the portion of the headgear and the outer layer of the two 3D fabrics, and wherein the edge of the outer 3D fabric overlaps with the edge of the inner 3D fabric.

[0234] In some embodiments, when in use, the outer layer of the two-layer 3D fabric is the outer layer of the two-layer 3D fabric that is away from the user's head when in use.

[0235] On the other hand, this disclosure relates to a headgear for use with a breathing mask, the headgear comprising a component formed of two layers of 3D fabric, wherein one or more edges of the two layers of 3D fabric are welded to a portion of the headgear, one layer of the two layers of 3D fabric overlapping the edge of the other layer of the two layers of 3D fabric, such that the weld includes a first region formed by the two sides of the two layers of 3D fabric and the portion of the headgear, and a second region formed by one layer of the two layers of 3D fabric and the portion of the headgear.

[0236] In some embodiments, the headgear according to the second aspect includes any one or more of the features described above in relation to the first aspect.

[0237] On the other hand, this disclosure relates to a headgear for use in conjunction with a breathing mask, wherein the headgear is at least partially made of 3D fabric and wherein welding is used to seal the edges and / or provide a structure and / or define a cushioning area for the headgear.

[0238] In some embodiments, overmolding is used to finish and seal the edges.

[0239] In some embodiments, a reinforcing member is applied to at least one area of ​​the headgear.

[0240] In some embodiments of the disclosed above aspects, the 3D fabric is a 3D spacer fabric.

[0241] On the other hand, this disclosure relates to a headgear for use with a breathing mask. The headgear includes a back panel formed of 3D fabric and having a top edge, a bottom edge, and side edges, the top edge being longer than the bottom edge, and the side edges connecting the top edge to the bottom edge. The headgear also includes a peripheral portion formed of a foam laminate and including straps for attachment to the mask; and stitching that secures the side edges of the back panel to the peripheral portion along a joint. The side edges form an angle with the top edge. And the angle Between 70 and 120 degrees.

[0242] In some embodiments, angle Between 85 degrees and 105 degrees.

[0243] In some embodiments, angle It is approximately 90 degrees.

[0244] In some embodiments, the top edge is curved.

[0245] In some embodiments, the back panel is formed from a folded and stitched 3D fabric sheet, and the back panel also includes a folded edge opposite to the seam allowance.

[0246] In some embodiments, the lateral edge of the seam head is positioned laterally inside the lateral edge of the rear panel.

[0247] In some embodiments, the lateral edge of the seam head is positioned transversely inside the seam.

[0248] In some embodiments, the distance between the lateral edges of the seam is less than the widest distance between the lateral edges of the back panel.

[0249] In some embodiments, the distance between the lateral edges of the seam is less than the width of the top edge.

[0250] In some embodiments, the width and length of the seam are consistent along the length of the joint.

[0251] In some embodiments, the seam is formed by using back-and-forth stitching.

[0252] In some embodiments, the seam is formed by using a zigzag stitch.

[0253] In some embodiments, the peripheral portion further includes: an upper stripe edge connected to the upper stripe of the peripheral portion; and a receiving edge engaging a lateral edge of the rear panel. The upper stripe edge and the receiving edge form a corner with an angle β greater than 70 degrees.

[0254] In some embodiments, angle β is approximately 90 degrees.

[0255] In some embodiments, the convex region of the lateral edge is connected to the top edge.

[0256] In some embodiments, the concave region of the lateral edge is connected to the bottom edge, wherein the convex region and the concave region are connected at an inflection point.

[0257] In some embodiments, the inflection point is located below the seam opening.

[0258] In some embodiments, the linear region of the lateral edge is connected to the bottom edge. The convex region and the linear region are connected at the tangent point.

[0259] In some embodiments, the cut point is located below the seam head.

[0260] In another aspect, this disclosure relates to a headgear for use with a breathing mask. The headgear includes: a back panel formed of 3D fabric and having a top edge, a bottom edge, and side edges, the top edge being longer than the bottom edge, and the side edges connecting the top edge to the bottom edge; a peripheral portion formed of a foam laminate and including straps for attachment to the mask; and a stitch that secures the side edges of the back panel to the peripheral portion along a joint. The side edges extend laterally outward from the top edge.

[0261] In some embodiments, the seam is formed by using back-and-forth stitching.

[0262] In some embodiments, the seam is formed by using a zigzag stitch.

[0263] In some embodiments, the lateral edges extend laterally outward from the bottom edge.

[0264] In some embodiments, the top edge is curved.

[0265] In some embodiments, the back panel is formed from a folded and stitched 3D fabric sheet, and the back panel also includes a folded edge opposite to the seam allowance.

[0266] In some embodiments, the lateral edge of the seam head is positioned laterally inside the lateral edge of the rear panel.

[0267] In some embodiments, the lateral edge of the seam head is positioned transversely inside the seam.

[0268] In some embodiments, the distance between the lateral edges of the seam is less than the widest distance between the lateral edges of the back panel.

[0269] In some embodiments, the distance between the lateral edges of the seam is less than the width of the top edge.

[0270] In some embodiments, the width and length of the seam are consistent along the length of the joint.

[0271] In some embodiments, the peripheral portion further includes: an upper stripe edge connected to the upper stripe of the peripheral portion; and a receiving edge engaging a lateral edge of the rear panel. The upper stripe edge and the receiving edge form a corner with an angle β greater than 70 degrees.

[0272] In some embodiments, angle β is approximately 90 degrees.

[0273] In some embodiments, the convex region of the lateral edge is connected to the top edge.

[0274] In some embodiments, the concave region of the lateral edge is connected to the bottom edge, wherein the convex region and the concave region are connected at an inflection point.

[0275] In some embodiments, the inflection point is located below the seam opening.

[0276] In some embodiments, the linear region of the lateral edge is connected to the bottom edge, wherein the convex region and the linear region are connected at a tangent point.

[0277] In some embodiments, the cut point is located below the seam head.

[0278] On the other hand, this disclosure relates to a headgear for use with a breathing mask. The headgear includes: a panel formed of a first material having a first set of mechanical properties, the panel including a top edge, a bottom edge, and side edges, the top edge being longer than the bottom edge, and the side edges connecting the top edge to the bottom edge; a peripheral portion formed of a second material having a second set of mechanical properties and including straps for attachment to the mask, wherein the second material and the second set of mechanical properties are more rigid than the first material and the first set of mechanical properties; and a stitching that secures the side edges of the rear panel to the peripheral portion along a joint. The side edges form an angle with the top edge. And the angle Between 70 and 120 degrees.

[0279] In some embodiments, angle Between 85 degrees and 105 degrees.

[0280] In some embodiments, angle It is approximately 90 degrees.

[0281] In some embodiments, the top edge is curved.

[0282] In some embodiments, the back panel is formed from a folded and stitched 3D fabric sheet, and the back panel also includes a folded edge opposite to the seam allowance.

[0283] In some embodiments, the lateral edge of the seam head is positioned laterally inside the lateral edge of the rear panel.

[0284] In some embodiments, the lateral edge of the seam head is positioned transversely inside the seam.

[0285] In some embodiments, the distance between the lateral edges of the seam is less than the widest distance between the lateral edges of the back panel.

[0286] In some embodiments, the distance between the lateral edges of the seam is less than the width of the top edge.

[0287] In some embodiments, the width and length of the seam are consistent along the length of the joint.

[0288] In some embodiments, the seam is formed by using back-and-forth stitching.

[0289] In some embodiments, the seam is formed by using a zigzag stitch.

[0290] In some embodiments, the peripheral portion further includes: an upper stripe edge connected to the upper stripe of the peripheral portion; and a receiving edge engaging a lateral edge of the rear panel. The upper stripe edge and the receiving edge form a corner with an angle β greater than 70 degrees.

[0291] In some embodiments, angle β is approximately 90 degrees.

[0292] In some embodiments, the convex region of the lateral edge is connected to the top edge.

[0293] In some embodiments, the concave region of the lateral edge is connected to the bottom edge, wherein the convex region and the concave region are connected at an inflection point.

[0294] In some embodiments, the inflection point is located below the seam opening.

[0295] In some embodiments, the linear region of the lateral edge is connected to the bottom edge, wherein the convex region and the linear region are connected at a tangent point.

[0296] In some embodiments, the cut point is located below the seam head. Attached Figure Description

[0297] The following figures and related descriptions are provided to illustrate various embodiments of this disclosure and do not limit the scope of this disclosure. Aspects of this disclosure and many accompanying advantages will become more readily understood as they are brought to a better understanding when referred to in conjunction with the accompanying figures in the following detailed description, wherein: Figure 1 It is a front view of a user wearing an interface arranged and configured according to certain features, aspects, and advantages of the present invention.

[0298] Figure 2 yes Figure 1 A side view of a user wearing the interface.

[0299] Figure 3 yes Figure 1 A perspective view of the face mask seal and face mask sealing clip of the interface.

[0300] Figure 4 yes Figure 3 Side view of the mask seal and mask seal clip.

[0301] Figure 5 It is arranged to connect to Figure 1 A perspective view of the bend component of the interface.

[0302] Figure 6 yes Figure 5 Side view of the pipe bending assembly.

[0303] Figure 7 yes Figure 5 Rear view of the pipe bending assembly.

[0304] Figure 8 yes Figure 5 A cross-sectional side view of the pipe bending assembly.

[0305] Figure 9 yes Figure 5 A cross-sectional perspective view of the pipe bending assembly.

[0306] Figure 10 This is a side view of another configuration of the pipe bending assembly.

[0307] Figure 11 yes Figure 10 Exploded view of the pipe bending assembly.

[0308] Figure 12 It is along Figure 10 The cross-sectional view obtained from line 12-12.

[0309] Figure 13 It is along Figure 10 The cross-sectional view obtained from line 13-13.

[0310] Figure 14 This is an enlarged cross-sectional side view of another bend assembly, in which the anti-suffocation valve baffle is in the open and closed positions.

[0311] Figure 15 yes Figure 14A magnified cross-sectional side perspective view of a portion of a bent pipe assembly.

[0312] Figure 16 yes Figure 14 An enlarged perspective view of a portion of the anti-suffocation valve of the bend assembly.

[0313] Figure 17 yes Figure 14 Another magnified perspective view of a portion of the anti-suffocation valve of the bend assembly.

[0314] Figure 18 yes Figure 14 A plan view of a portion of the anti-suffocation valve of the bend assembly.

[0315] Figure 19 yes Figure 14 A side view of a portion of the anti-suffocation valve of the bend assembly.

[0316] Figure 20 This is a perspective view of another embodiment of the anti-suffocation valve.

[0317] Figure 21 yes Figure 20 Side view of the valve.

[0318] Figure 22 This is a cross-sectional view of the patient interface component.

[0319] Figure 23A This is a perspective view of the configuration of the connector and bend assembly.

[0320] Figure 23B yes Figure 23A A perspective view of the connector and bend assembly, with a portion of it removed.

[0321] Figure 23C yes Figure 23A Alternate perspective view of connectors and bends.

[0322] Figure 23D yes Figure 23A Cross-sectional view of the connector and bend assembly.

[0323] Figure 24A yes Figures 23A to 23D Side view of the connector and bend assembly shown.

[0324] Figure 24B yes Figures 23A to 23D A perspective view of the connector and bend assembly shown.

[0325] Figure 24C yes Figures 23A to 23D Alternate perspective view of the connector and bend assembly shown.

[0326] Figure 25A yes Figures 23A to 23D A perspective view of the bent pipe connector shown.

[0327] Figure 25B yes Figures 23A to 23D A perspective view of the bent pipe connector shown.

[0328] Figure 25C yes Figures 23A to 23D The side view of the bend connector shown.

[0329] Figure 25D yes Figures 23A to 23D The front view of the bend connector shown.

[0330] Figure 25E yes Figures 23A to 23D The cross-sectional view of the bent pipe connector is shown.

[0331] Figure 25F yes Figures 23A to 23D The top perspective view of the bent pipe connector shown.

[0332] Figure 26 This is a cross-sectional side view of the bend assembly according to the invention, which incorporates an anti-suffocation valve.

[0333] Figure 27 From Figure 26 Enlarged perspective view below the bend assembly.

[0334] Figure 28A Show Figure 26 and Figure 27 Top perspective view of the anti-suffocation valve of the bend assembly.

[0335] Figure 28B Show Figure 26 and Figure 27 Side perspective view of the anti-suffocation valve of the bend assembly.

[0336] Figure 28C Show Figure 26 and Figure 27 Bottom perspective view of the anti-suffocation valve of the bend assembly.

[0337] Figure 29 yes Figures 26 to 2 Plan view of valve 8.

[0338] Figure 30 yes Figures 26 to 29 Front view of the valve.

[0339] Figure 31 Figure 28 to Figure 30 A cross-sectional side view of the valve, showing optional, non-limiting example dimensions.

[0340] Figure 32 It is a view of the respiratory system, including the flow generator, humidifier, and user interface.

[0341] Figure 33A The diagram shows components for deflecting airflow in a two-part spherical joint socket and a connecting housing, according to one embodiment.

[0342] Figure 33B Show Figure 33A The front view of the two-part spherical joint socket and the connecting housing.

[0343] Figure 33C Show Figure 33A The two parts of the spherical joint socket and the connecting shell are shown in a side sectional view.

[0344] Figure 34A A top cross-sectional view of the seal between the socket and the connecting housing is shown according to at least one embodiment.

[0345] Figure 34B Shown in Figure 34A A close-up cross-sectional view of the L-shaped side of the protruding portion of the connecting shell between the bearing socket and the connecting shell.

[0346] Figure 35A A front view of the two-part spherical joint socket and the deflection airflow in the connecting housing according to another embodiment is shown.

[0347] Figure 35B Show Figure 35A The two parts of the spherical joint socket and the connecting shell are shown in the side cross-sectional view.

[0348] Figure 35C Show Figure 35A A top cross-sectional view of the two parts of the spherical joint socket and the connecting shell.

[0349] Figure 36 Details of the seal between the socket and the connecting housing according to at least one embodiment are shown.

[0350] Figure 37A The diagram shows a top cross-sectional view of deflected airflow in a spherical connector socket with a recessed flow path according to one embodiment.

[0351] Figure 37B Showing a ball joint without truncated top Figure 37A A top-view cross-sectional view of the spherical joint socket.

[0352] Figure 37C Show Figure 37A A side view cross-sectional view of the deflected airflow in the spherical joint socket.

[0353] Figure 37D Show Figure 37AThe top cross-sectional view of the spherical joint socket shows the generally arc-shaped second load-bearing area.

[0354] Figure 37E Showing a configuration in "unfolding bend". Figure 37A A top-view cross-sectional view of the spherical joint socket.

[0355] Figure 38A A top cross-sectional view of the deflected airflow in a spherical joint socket with a recessed flow path according to another embodiment is shown.

[0356] Figure 38B Show Figure 38A A side view cross-sectional view of the deflected airflow in the spherical joint socket.

[0357] Figure 38C It shows Figure 38A A close-up side-view cross-sectional view of the deflected airflow in the spherical joint socket.

[0358] Figure 38D Show Figure 32 A top cross-sectional view of the spherical joint socket of A shows the generally arc-shaped second bearing area.

[0359] Figure 38E Show Figure 38A A top cross-sectional view of a spherical joint socket, wherein the end of the truncated spherical joint is completely suspended above the spherical joint mating area within the socket.

[0360] Figure 39A A perspective view of the socket is shown, illustrating the arrangement of the array of holes.

[0361] Figure 39B A perspective view of the socket is shown, illustrating an alternative arrangement of the array of holes.

[0362] Figure 39C A perspective view of the socket is shown, illustrating an alternative arrangement of the array of holes.

[0363] Figure 39D A perspective view of the socket is shown, illustrating the arrangement of the array of elongated holes.

[0364] Figure 40A Show Figures 37A to 37E and Figures 38A to 38E The arc length of the bearing area of ​​the spherical joint bearing socket with a concave flow path.

[0365] Figure 40B Show Figures 38A to 38E The depth of the deflecting air passage in the spherical joint socket with a concave flow path.

[0366] Figure 40C Show Figures 38A to 38EThe arc length of the bearing area of ​​the spherical joint bearing socket with a concave flow path.

[0367] Figure 40D Show Figures 38A to 38E The inner diameter of the connecting shell of the spherical joint bearing socket with a concave flow path.

[0368] Figure 40E Show Figures 38A to 38E The fixed area of ​​the bearing region of the spherical joint bearing socket with a concave flow path.

[0369] Figure 41A A front view of a breathing mask assembly with an integrated elbow socket is shown.

[0370] Figure 41B Show Figure 41A Rear view of a breathing mask assembly with an integrated elbow socket.

[0371] Figure 41C Show Figure 41A A side view of a breathing mask assembly with an integrated elbow socket.

[0372] Figure 41D Show Figure 41A A close-up perspective view of the rear of a breathing mask assembly with an integrated elbow socket.

[0373] Figure 41E Show Figure 41A A close-up perspective view of the front of a breathing mask assembly with an integrated elbow socket.

[0374] Figure 42A A front view of an alternative breathing mask assembly with an integrated elbow socket is shown.

[0375] Figure 42B Show Figure 35A A cross-sectional view of an alternative breathing mask assembly with an integrated elbow socket along line 36B-36B.

[0376] Figure 43 It is a cross-sectional view of a 3D spacer fabric, showing two outer fabric pieces and the internal spacer fibers or filaments between the pieces.

[0377] Figure 44 is a perspective view of the full-body patient interface and headgear components.

[0378] Figure 45 This is an isometric view of the full-face headgear configuration when laid flat.

[0379] Figure 46AThis is a cross-sectional view of the edge of the spacer fabric, finished using welding and die-cutting techniques.

[0380] Figure 46B It is a cross-sectional view of the spaced fabric edge, which is finished by welding the upper and lower surfaces together at the center of the fabric.

[0381] Figure 46C It is a cross-sectional view of the edge of the spacer fabric, which is finished by folding the upper surface and welding it to the lower surface.

[0382] Figure 46D It is a cross-sectional view of the edge of the spacer fabric, which is finished by welding individual finishing components to the edge of the spacer fabric.

[0383] Figure 46E It is a cross-sectional view of the edge of the spacer fabric, which is finished by molding the beaded edge onto the edge of the spacer fabric.

[0384] Figure 46F This is a cross-sectional view of the edge of the spacer fabric, which is finished by allowing a plastic material to penetrate through the spacer fabric.

[0385] Figure 46G This is a cross-sectional view of the spacer fabric edge, which is finished by sealing and trimming the spacer fabric using a heat-sealing knife technique.

[0386] Figure 47A The headgear shown includes spaced fabric laid flat.

[0387] Figure 47B Showing the merge in Figure 47A Details of the spacer fabric panels in the headgear.

[0388] Figure 48 A headgear arrangement is shown in which, during use, the bottom edge of an interlaced fabric panel is positioned above or across the user's neck.

[0389] Figure 49 A headgear arrangement is shown, the headgear arrangement having a back panel formed of two layers of spacer fabric and a peripheral portion formed of another headgear material extending around the entire periphery of the spacer fabric.

[0390] Figure 50 A headgear arrangement with a back panel is shown, the back panel being formed of two layers of spacer fabric folded from a spacer fabric sheet or blank.

[0391] Figure 51 The headgear arrangement is shown as consisting of two layers of spaced fabric welded together along each lateral edge and sewn together along the edge opposite to the fold.

[0392] Figure 52The headgear arrangement with curved edges and pleats is shown.

[0393] Figure 53 The headgear arrangement is shown, consisting of two layers of spacer fabric welded to the upper and lower stripes respectively along the upper and lower edges.

[0394] Figure 54 The diagram shows a headgear arrangement formed by spaced fabric that wraps around other headgear materials to have folds at the upper and lower edges of the back panel.

[0395] Figure 55 yes Figure 54 The cross-section of the back panel of the headgear.

[0396] Figure 56 It is a reference Figure 51 The embodiment describes a cross-section of the rear panel of the headgear.

[0397] Figure 57 Another embodiment of the headgear is shown lying flat.

[0398] Figure 58A The blank of the spacer fabric is shown.

[0399] Figure 58B This shows a folded fabric to form two layers of spacer fabric. Figure 58A The perspective outline of the spacer fabric blank.

[0400] Figure 58C This shows a folded fabric to form two layers of spacer fabric. Figure 58A A side view of the spaced fabric blank.

[0401] Figure 58D Another blank is shown for forming the spacer fabric of the back panel, which includes two layers of spacer fabric.

[0402] Figure 59A The image shows the material stack before welding.

[0403] Figure 59B Showing welded together in a welded joint Figure 59A Enlarged view of the material in the image.

[0404] Figure 60 A schematic graph is shown to illustrate the optimal weld thickness.

[0405] Figure 61 This illustrates a headgear arrangement having a back panel formed from a 3D fabric that is sewn to a peripheral portion made of foam and fabric laminate.

[0406] Figure 62An alternative headgear arrangement is shown, featuring a back panel formed of 3D fabric stitched to a peripheral portion made of foam and fabric laminate.

[0407] Figure 63 Showing flat Figure 62 The rear panel of the headgear is arranged in the middle.

[0408] Figure 64 Show Figure 62 The back panel and surrounding parts of the headgear are arranged in the middle.

[0409] Figure 65 yes Figure 62 A close-up view of the joint between the rear panel and the surrounding parts of the head-mounted device.

[0410] Figure 66 Show Figure 62 The surrounding part of the headgear arrangement.

[0411] Figure 67 It is along Figure 62 A close-up view of the stitching at the joints of the headgear arrangement.

[0412] Figure 68 The headgear arrangement with gathered seams is shown.

[0413] Figure 69 The other end of the headgear arrangement is shown, featuring a gathered seam.

[0414] Figure 70 It is a close-up view of the seam that gathers along the joint between the rear panel and the surrounding parts.

[0415] Figure 71 It is a close-up view of the seam that converges along the joint between the rear panel and the surrounding parts, where the upper corner of the rear panel is deformed.

[0416] Figure 72 An alternative headgear arrangement with alternative lateral edge arrangements is shown.

[0417] Figure 73 This illustrates another alternative headgear arrangement with an alternative lateral edge arrangement.

[0418] Figure 74 Show Figure 73 An alternative headgear arrangement, wherein the size of the seam head is determined relative to the lateral edge of the back panel.

[0419] In the accompanying drawings, the first digit of each reference numeral typically indicates the drawing in which the element first appears. Reference numerals may be repeated throughout the drawings to indicate correspondence between referenced elements. However, using different numerals does not necessarily indicate a lack of correspondence between elements. Moreover, conversely, repeating numerals does not necessarily indicate that the elements are identical. Detailed Implementation

[0420] While certain preferred embodiments and examples are disclosed below, the subject matter of the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses, as well as modifications and equivalents thereof. Therefore, the scope of the appended claims is not limited to any particular embodiment described below. For example, in any method or process disclosed herein, the actions or operations of the method or process can be performed in any suitable order and are not necessarily limited to any specifically disclosed order. Various operations may be described sequentially as multiple discrete operations in a manner that may aid in understanding certain embodiments; however, the order of description should not be construed as implying that these operations are sequentially related. Additionally, the structures, systems, and / or apparatuses described herein may be embodied as integrated components or separate components. Certain aspects and advantages of these embodiments are described for the purpose of comparing various embodiments. All such aspects or advantages are not necessarily achieved by any particular embodiment. Thus, for example, various embodiments may be implemented in a manner that achieves or optimizes one or a set of advantages as taught herein, without necessarily achieving other objects or advantages as may also be taught or suggested herein.

[0421] Details relating to several illustrative embodiments for implementing the apparatus and methods described herein are now described with reference to the accompanying drawings. Numerous specific details are set forth in the following description to provide a more complete understanding of the various embodiments of this disclosure. However, it will be apparent to those skilled in the art that the systems and methods of this disclosure can be practiced without one or more of these specific details.

[0422] To facilitate understanding of the systems and methods discussed herein, several terms are defined below. The terms defined below, as well as other terms used herein, should be interpreted broadly to include, but are not limited to, the definitions provided, the common and conventional meanings of the terms, and / or any other implied meanings of the corresponding terms. Therefore, the definitions below do not limit the meaning of these terms, but are merely illustrative definitions.

[0423] Regarding dimensions, the term "approximately" should be understood to mean within standard manufacturing tolerances or deviations that arise and / or are foreseeable during manufacturing. Furthermore, the term "approximately" may be extended to and include dimensions that can be rounded to the stated value.

[0424] The term should generally be understood as meaning "for most purposes". For example, a component that is generally cylindrical does not necessarily need to conform to a perfect cylinder (a surface or solid formed by two parallel planes constrained and moved by a straight line parallel to the given plane, the surface or solid following a curve constrained by the planes and lying in a plane perpendicular or inclined to the given plane). Instead, a substantially cylindrical component should be understood as quasi-cylindrical because it has a circular profile along its cross-section and an elongated longitudinal profile.

[0425] The term "respiratory mask" is a broad term and is given its common and conventional meaning to those skilled in the art (that is, it is not limited to a special or custom meaning) and includes (but is not limited to) various user interfaces for NIV and CPAP.

[0426] The term "sealing" refers to a substantially, but not necessarily, airtight seal. For example, a pad can be sealed against a user's face in a manner that allows a large volume of airflow to and from the user through the pad, while potentially allowing a small amount of gas to escape from between the pad and the user's face without interrupting the large volume of airflow.

[0427] The term "top" refers to the direction closest to the user's nose when in use.

[0428] The term "bottom" refers to the direction closest to the user's lower lip when in use.

[0429] The term static noise refers to environmental noise originating from the respiratory system during use.

[0430] The term dynamic noise refers to additional noise from the respiratory system during use that exceeds ambient noise, caused by breathing due to increases and decreases in airflow and velocity.

[0431] The term "perimeter" refers to the boundary or edge of a region or object. For a ring-shaped (or toroidal) object, such as a hollow cylinder, the outer perimeter refers to the outermost boundary or edge of the hollow cylinder facing its surroundings. The inner perimeter refers to the inner boundary or edge of a hollow cylinder facing its central hole. For a solid object with an internal hole, the perimeter of the hole refers to the boundary or edge along the hole facing the center of the hole.

[0432] First refer to Figure 1 and Figure 2The interface 100 is shown in a suitable location on the user U. Interface 100 includes an interface usable in the field of respiratory therapy. Interface 100 has specific practicality in forms of positive pressure respiratory therapy. For example, interface 100 can be used to administer continuous positive airway pressure (“CPAP”) therapy. Furthermore, interface 100 can be used with variable positive airway pressure (“VPAP”) therapy and bilevel positive airway pressure (“BiPAP”) therapy. The interface can be used with any suitable CPAP system.

[0433] Interface 100 may include any suitable mask configuration. For example, certain features, aspects, and advantages of the invention may be used with nasal masks, full-face masks, oronasal masks, or any other positive pressure masks. The mask shown is a full-face mask. The interface 100 shown typically includes a mask assembly 102, a connection port assembly 104, and a headgear assembly 106.

[0434] Reference Figure 3 and Figure 4 The mask assembly 102 typically includes a mask seal 110 and a mask base 114, the mask seal including a mask sealing clip 112. The mask sealing clip 112 preferably connects the mask seal 110 to the mask base 114. Although the mask seal 110 and mask sealing clip 112 shown are formed separately and then fixed together, in some configurations, the mask seal 110 and mask sealing clip 112 may be integrated into a single component. In some configurations, the mask seal 110 is overmolded onto the mask sealing clip 112.

[0435] Reference Figure 3 Compared to the face mask seal 110, the face mask clip 112 is relatively more rigid, stiffer, or less flexible. In some configurations, the face mask clip 112 is formed of polycarbonate material. In some configurations, at least a portion of the face mask clip 112 is formed of polycarbonate or other rigid or semi-rigid materials. In some configurations, the face mask clip 112 is at least partially formed of silicone or another suitable material. In such configurations, at least the silicone portion of the face mask clip 112 can be formed relatively thicker compared to the more flexible portion of the face mask seal 110. In the illustrated configuration, the face mask clip 112 provides structural support to the face mask seal 110.

[0436] The illustrated mask seal also includes a generally centrally located passage 144 defined by wall 136. In the illustrated configuration, wall 136 typically encloses passage 144. Preferably, wall 136 is generally cylindrical in configuration and extends through wall 126. Other configurations are also possible.

[0437] refer to Figure 4The mask sealing clip 112 is preferably arranged such that it is substantially flush with the inner edge 150 of the mask seal 110. In the illustrated configuration, the mask seal 110 includes a relatively small radius portion 152 that engages with the upper portion 154. The upper portion 154 of the mask seal 110 is configured to extend above the user's nasal region. In some configurations, the upper portion 154 is configured to extend above the user's bridge of the nose region.

[0438] The upper portion 154 of the sealing member 110 is connected to the lower portion 156. The lower portion 156 extends outward from the side of the mask sealing clip 112. Furthermore, the lower portion 156 is wound rearward and inward, as... Figure 4 As shown. Simultaneously, on the proximal side of the full-face mask assembly 102, the upper portion 154 and the lower portion 156 combine to define a face contact flange 160, which in... Figure 10 As shown, the face contact flange 160 is configured to be located below the user's lower lip, extending along the outside of the mouth, upward along the cheekbone, and across the user's nose. Therefore, the shown face contact flange 160 defines a generally teardrop-shaped opening 162. When the mask assembly 102 is placed on the user's face, the flange 160 will lie flat on the user's nose, cheekbone, outside of the mouth, and below the lower lip. With a positive pressure air supply, the mask seal 110 will inflate like a balloon and seal against the user's face to reduce or eliminate the possibility of leakage between the flange 160 and the user's face.

[0439] The upper portion 154 of the mask seal 110 is designed to flip over onto the outer surface 130 of the mask assembly 102. In the illustrated configuration, the outer surface of the mask seal 110 smoothly flips over to abut the outer surface of the mask seal clip 112, such that the outer surface of the mask seal clip 112 forms a support surface. In some configurations, the outer surface 130 onto which the upper portion 154 flips over includes at least a portion of the outer surface of the mask seal clip 112. In some configurations, the outer surface 170 onto which the upper portion 154 flips over includes almost the entire outer surface of the mask seal clip 112. In some configurations, the upper portion 154 flips over onto another portion of the mask seal 110. In some configurations, the upper portion 154 flips over onto the mask seal base 114.

[0440] For reference Figure 1 and Figure 2 The mask assembly 102 includes a mask base 114 that is more rigid than the mask seal 110. The mask base 114 can be formed of any suitable material. In some configurations, the mask base 114 is formed of polycarbonate material, allowing it to flex to connect with the mask seal 110 and / or the mask seal clip 112.

[0441] The central channel 144 may be arc-shaped to receive the spherical end 220 of the rotating bend 222, such as... Figure 5 As shown. (As in...) Figure 6 As better shown, the spherical end 220 has a shaped surface 224 that snaps into a shaped surface 214 formed in the mask base 114. The connection between the two shaped surfaces 214, 224 allows the surfaces to slide freely relative to each other, making it easy to change the position of the rotating bend 222. In some configurations, the bend 222 can be configured to rotate or tumble without a spherical joint configuration.

[0442] refer to Figure 2 In addition to the strap 260, the headgear assembly 106 also includes a rear strap 280 and a top strap 282. Other headgear assemblies may also be used. The rear strap 280 extends around the back of the user U's head, generally above the back of the neck but generally below the occipital protuberance. At a position behind the user's ear, the rear strap 280 forks into an upper arm 284 and a lower arm 286. The upper arm 284 curves upward to a position above the user's ear, then curves downward to a position generally in front of the user's ear. The lower arm 286 curves downward to a position generally below the user's ear and extends slightly forward of the ear.

[0443] The strap 260 can be connected to the rear strap 280 in any suitable manner. In the illustrated configuration, the strap 260 is connected to the upper arm 284 and the lower arm 286, respectively. Preferably, the upper arm 284 and the lower arm 286 are more rigid than the strap 260, such that the arms 284, 286 substantially maintain their shape when the headgear assembly 106 is worn. In some configurations, each of the upper arm 284 and the lower arm 286 supports its own weight. In some configurations, each of the upper arm 284 and the lower arm 286 is configured to prevent tangling during wear. For example, the arms 284, 286 have sufficient torsional stiffness to reduce the likelihood of tangling when worn.

[0444] Preferably, the strap 260 is connected to at least one of the upper arm 284 and lower arm 286 at a position in front of the ear. This configuration helps the user position the strap 260 effortlessly. Furthermore, since the strap 260 in the illustrated configuration is embedded in the clamp 252, the ends of the upper arm 284 and lower arm 286 may include slots 290, 292, allowing the strap 260 to pass through them. Additionally, the strap 260 may include an adjustment mechanism 294, such as a Velcro or buckle configuration. The adjustment mechanism 294 allows adjustment of the force between the mask seal 110 and the user's face. Any suitable adjustment mechanism 294 can be used.

[0445] like Figure 2 As shown, the top strap 282 is preferably flexible and has an adjustable length. The top strap 282 passes through the slot 296 and connects to the upper arm 284, reducing the likelihood of the upper arm 284 sliding down the user's head and contacting the user's ear. Preferably, the top strap 282 connects to the upper arm 284 at a position generally above the user's ear.

[0446] Advantages, such as Figure 1 and Figure 2 As shown, when connected to the mask base 114 by moving along direction C, the strap 260 applies a force in the direction F of the arrow, said direction C being generally perpendicular to the direction of the force F. In other words, the strap 260 is tensioned by pulling forward, and the clamp 252 is connected to the mask base 114 by moving in a direction perpendicular to the forward pull. This configuration facilitates securing the interface 100 to the user's face.

[0447] Refer again Figure 5 The bend 222 is connected to the conduit 300 via a detachable rotating assembly 302. For example... Figure 8 As shown in the cross-sectional view, the bend 222 includes a rod 304, which includes an inner wall 306 at its base. The inner wall 306 includes a notch 308.

[0448] The sleeve 310 includes a flange 312 received within a recess 308. The sleeve 310 can be secured to a position within the bend 222 using any suitable technique. The sleeve 310 includes a generally cylindrical outer wall 314. The flange 312 includes a section extending outward to connect to a lever 316. Preferably, the flange 312 and the lever 316 are integrally formed. (Reference) Figure 9 The lever 316 includes a lowerly inwardly extending latch 320 and is pivotable about the section that connects the lever 316 to the flange 312. Therefore, pressing the upper portion 322 of the lever 316 inward causes the latch 320 to move away from the generally cylindrical outer wall 314 of the sleeve 310.

[0449] The rotating member 330 includes a generally cylindrical inner wall 332. The inner wall 332 slides on the outer wall 314 of the sleeve 310, creating a sliding engagement between the rotating member 330 and the sleeve 310. The upper portion 334 includes a shoulder 336. The latch 320 of the lever 316 can engage with the shoulder 336 to hold the rotating member 330 in an axial position on the sleeve 310. When the upper portion 322 of the lever 316 is depressed, the latch 320 moves away from the shoulder 336, which allows the rotating member 330 to be removed from the sleeve 310.

[0450] A baffle 350 can be installed between the rod 304 and the sleeve 310. In the illustrated configuration, the baffle 350 extends from the base 354, sandwiched between the rod 304 and the sleeve 310, into the flow channel 352. The baffle 350 can be positioned about axis X (see [reference]). Figure 9 ) Upward pivot (such as Figure 8 As shown, see arrow P) away from sleeve 310, allowing the flow from the positive pressure generator to continue substantially unobstructed through interface 100 to the user. When the positive pressure source stops providing pressurized airflow, baffle 350 pivots downwards to contact sleeve 310 to seal flow passage 352. In some configurations, baffle 350 will not fully contact sleeve 310. In some configurations, baffle 350 will not seal passage 352 when in the downward position.

[0451] refer to Figure 9 Port 360 is defined as passing through bend 222 above baffle 350. Port 360 is preferably positioned along a portion of bend 222 near axis X. In some configurations, port 360 is positioned to be substantially shielded by baffle 350 from the intake airflow. In other words, baffle 350 moves to a position that at least partially or completely covers port 360 as air causes baffle 350 to pivot away from sleeve 310.

[0452] In some configurations, port 360 extends through the wall of bend 222, which includes a generally planar inner wall 362. As the baffle moves upward away from flange 312 of sleeve 310, the generally planar inner wall 362 helps baffle 350 to generally seal port 360.

[0453] In some configurations, lever 316 covers most of port 360, making port 360 typically obscured and invisible. However, as... Figure 8 As shown, the gap 364 preferably surrounds at least a portion of the lever 316, allowing relatively free airflow through the port 360 when the baffle 350 is not covering it. Furthermore, in some configurations, the port 360 and the lever 316 are positioned on the same side of the bend 222 as an opening 370 defined within the spherical end 220, which is located within the face mask assembly 102 when the connecting port assembly 104 is assembled to the face mask assembly 102. Advantageously, this position places the port 360 in a user-facing position on the bend 222. This position further obscures the port 360, making it invisible during use, resulting in a more aesthetically pleasing configuration. Moreover, because the airflow through the port 360 is very sparse, positioning the port 360 towards the user will not cause any significant discomfort to the user.

[0454] Although not shown, bend 222 may also include one or more deflection vents. The deflection vents are preferably positioned in a forward-facing orientation so that any deflection does not directly impact the user.

[0455] Figures 10 to 13 Another configuration of the bend assembly 302 is shown in the image. For example... Figure 11 As shown, the bend assembly 302 includes a bend 222, a sleeve 310, and / or a swivel 330. In some configurations, the bend assembly 302 includes only the bend 222 and the sleeve, omitting the swivel 330. The swivel may be permanently or removably attached to the sleeve 310 and the bend 222; in some configurations, the swivel 330 is integrally formed with the end of the delivery conduit. An anti-suffocation valve baffle 350 is positioned above the sleeve 310 such that the anti-suffocation valve baffle at least partially obstructs the flow passage 352 of the sleeve. The bend assembly 302 functions similarly to... Figures 5 to 9 The pipe bending assembly 302; however, Figures 10 to 13 The bend assembly 302 provides a way for the baffle 350 to descend to its closed position (e.g., Figure 12 and 13 (As shown) provides the additional benefit of guiding the gas away from the patient.

[0456] refer to Figure 11 The sleeve 310 preferably includes two or more cut areas or notches 356. The notches 356 can have any suitable shape, and in the illustrated configuration, the notches 356 comprise a semi-circular shape extending upward into the sleeve 310. The sleeve 310 also includes at least one lug 357, preferably two or more lugs 357. Preferably, each of the lugs 357 extends about an arc of approximately 70 degrees. More preferably, each of the lugs 357 is generally centered between two notches 356, and each of the lugs 357 extends about 70 degrees around the outer surface of the sleeve 310.

[0457] The rotating component 330 is preferably configured to be generally cylindrical. For example... Figure 11 As shown, the rotating member 330 has an inwardly extending ridge 358. The ridge 358 preferably surrounds the entire inner surface. In some configurations, the ridge 358 may be interrupted. However, preferably, the ridge 358 does not have any interruption large enough to accommodate the entire lug 357, such that the ridge 358 and the lug 357 can engage to hold the rotating member 330 mounted on the sleeve 310. When the rotating member 330 is assembled to the sleeve 310, the notch 216 allows the lug 220 to deflect inward, allowing the lug 357 to slide over the ridge 358 and then quickly snap outward to secure the lug 357 below the ridge 358.

[0458] The bend 222 includes an opening 420 on its side, which is in fluid communication with an air vent 422. For example... Figure 12 and Figure 13 As shown, the air ventilation channel 422 is formed by the gap between the inner wall 362 and the outer wall 424 of the bend.

[0459] When the baffle 350 descends to its closed position, as Figure 12 and Figure 13 As shown, the air exhaled by the user enters the opening 370 of the bend 222. The exhaled air flows through the port 360 in the inner wall 362 of the bend and through the ventilation channel 422 until it exits the bend 222 through the opening 420.

[0460] Figures 10 to 13 The configuration provides a reduced overall length and improves product aesthetics by eliminating the unsightly hole located at the front of the bend 222. Furthermore, Figures 10 to 13 The configuration improves patient comfort by preventing air from being directed toward the user. Alternatively, the opening 420 directs airflow away from the side of the bend 222 and away from the patient.

[0461] For further reference Figures 14 to 19 Another configuration of the bend assembly 702 includes a bend 722 and a sleeve 710. A rotating member 330 as described above can also be provided, but... Figures 14 to 19 It is not shown in the middle.

[0462] An anti-suffocation valve (AA valve) 750 is provided and disposed on the sleeve 710 such that it at least partially obstructs the flow passage 352 of the sleeve. The bend assembly 702 functions similarly to... Figures 10 to 13 The bend assembly 302, and when the baffle 752 of the AA valve 750 descends to its closed position (i.e., as Figure 14 (As shown in the generally horizontal position) When the flow channel 352 through the sleeve 710 is closed, the gas is similarly directed away from the patient.

[0463] Valve 750 includes a generally planar valve baffle 752 hinged to a baffle support 754. The baffle support 754 may be integrally formed with the valve baffle 752 and may include one or more orientation features that facilitate proper orientation and installation of the valve 750 on the sleeve 710. In this example, the orientation features include a slot 756 formed in the underside of the baffle support 754 that receives a corresponding protrusion 758 disposed on the upper portion of the sleeve 710. The engagement between the slot 756 and the protrusion 758 helps hold the valve 750 on the sleeve 710 during assembly of the bend assembly 702 and helps to properly align the valve 750 relative to the sleeve 710 and bend 722 and relative to the axis of the flow passage 352 of the sleeve. The slot 756 and the protrusion 758 also prevent the valve 750 from being mounted upside down on the sleeve 710, that is, from the baffle 752 and the baffle support 754. Figure 14 The orientation shown is rotated 180 degrees.

[0464] Valve 750 includes a hinge 760 that pivotally mounts a baffle 752 onto a support 754. The hinge 760 may be integrally formed with both the baffle 752 and the support 754. The hinge 760 includes a relatively thin strip made of a material more flexible than the baffle 752 and the support 754, allowing the thicker baffle 752 to pivot about the support 754 from a generally horizontal position to a generally vertical position. In the generally horizontal position, the baffle 752 closes a flow passage 352 through the sleeve 710; in the generally vertical position, the baffle 752 opens the flow passage 352 in the sleeve 710 but closes an air vent passage 422 formed in the bend 722.

[0465] The valve baffle 752 includes a beaded edge, ridge, or protrusion 762 projecting from the upper surface 764 of the baffle 752. Thus, the beaded edge 762 extends from the upper surface 764 of the baffle 752. When the baffle 752 is in a generally vertical position where it opens the flow passage 352 in the sleeve 710 but closes the air vent passage 422 formed in the bend 722, the beaded edge 762 contacts the portion of the bend 722 surrounding the vent passage 422 and forms a discontinuous sealing surface 764 that abuts against the bend 722 and seals and closes the vent passage 422. The beaded edge 762 thus forms a sealing surface 764 having a relatively small sealing area relative to the area of ​​the valve baffle 752 itself. That is, when the baffle 752 is in a generally vertical position, the area 764 of the beaded edge 762 that abuts against the bend 722 and seals it is relatively small, but still sufficient to seal and close the vent passage 422.

[0466] When the bend 722 has undergone multiple cleaning cycles, the plastic surface of the bend 722 may become degraded, making it easier for water to adhere to those surfaces. As a result, the wetting angle of the water / plastic interface increases, causing water droplets to remain on the contact surface of the bend 722 instead of forming droplets and rolling off the contact surface.

[0467] A potential problem with existing AA valves is that the relatively large sealing surface of the flat valve baffle may cause water to accumulate between the contact surface of the bend and the valve baffle. The surface tension of water can act as an adhesive, holding the valve baffle against the contact surface of the bend, keeping the valve baffle in a generally vertical position, thereby sealing the vent passage 422.

[0468] Providing a beaded flange 762 on the valve baffle 752 results in a significantly smaller relative sealing surface that contacts the inner sealing surface of the bend. This leads to a lower water volume between the baffle and the bend, thereby reducing the force that the surface tension of the water can resist and allowing the valve baffle 752 to be released more easily from the bend's contact surface. Therefore, providing the beaded flange 762 reduces or prevents the valve baffle 752 from sticking to the location where the vent passage 422 is closed.

[0469] In this example, the bead edge 762 includes an arcuate curve portion 765 that follows the curved periphery of the valve baffle 752 away from the hinge 760, and a linear portion 766 that extends along the straight edge of the valve baffle 752 toward the hinge 760. Thus, in this example, the bead edge 762 extends substantially around the entire periphery of the valve baffle to the hinge 760, and is generally 'n'-shaped when viewed in a plane.

[0470] In this example, when viewed from the side, the bead edge 762 is tapered. Therefore, the portion of the bead edge 762 further from the hinge 760 protrudes further from the planar upper surface of the baffle 752 compared to the portion closer to the hinge 760. In this example, the apex of the arcuate bead edge portion 764 extends further from the baffle 752 than the linear bead edge portion 766. The bead edge tapers uniformly from the arcuate portion 764 to the linear portion 766, such that the bead edge 762 fuses into the upper planar baffle surface adjacent to the hinge 760. This taper along the longitudinal axis of the valve baffle 752 allows the bead edge 762 to completely abut against the sealing surface of the bend 722 around the entire periphery of the baffle 752, sealing the vent passage 422. Therefore, when in the vertical state of closing the vent passage 422, the baffle 752 is slightly tilted from said vertical when sealing against the bend 722.

[0471] In this example, when viewed from the side, the profile of the bead flange 762 is rounded or chamfered. Therefore, the sealing surface 764 of the bead flange 762 (i.e., the portion of the bead flange 762 that protrudes most from the valve baffle 752) can be flat. However, the sidewalls of the bead flange supporting the sealing surface 764 can be shaped and can be, for example, rounded or chamfered. The shaped sidewalls 768, 770 of the bead flange 762 can extend to the full distance of the valve baffle 752, or can be shaped only adjacent to the sealing surface 764. For example, from... Figure 17 As can be seen, the profile of one sidewall 770 of the bead flange 762 can differ from the profile of the other sidewall 772 of the bead flange 762. In this example, the inner sidewall 768 of the bead flange 762 curves downward from the sealing surface 764 and merges into the upper planar surface 772 of the valve baffle 752 with a relatively large radius of curvature (i.e., a relatively gentle curve from the bead flange sealing surface 764 to the valve baffle 752). In contrast, the outer sidewall 770 of the bead flange 762 is straight and has a relatively steep angle of inclination from the bead flange sealing surface 764 to the valve baffle 752.

[0472] Other profiles and shapes for the bead flange are envisioned. For example, the bead flange may simply include a square, rectangular, elongated, or triangular cross-sectional profile. For example, the cross-section of the bead flange may vary along its length. Part or all of the bead flange 762 may include a semi-circular or arc-shaped cross-sectional profile. The sidewalls of the bead flange 762 may not be rounded or chamfered, but may simply be straight edges extending between the bead flange sealing surface 764 and the valve baffle 752. These straight edges may be inclined or substantially perpendicular to the plane of the valve baffle 752.

[0473] refer to Figure 20 and Figure 21 Another embodiment of the anti-suffocation valve 850 includes many features similar to those of the valve 750 described above. However, in this example, the valve 850 includes a beaded rim 862 that extends around the entire periphery of the valve baffle 852, with a portion of the beaded rim 862 extending beyond the hinge 760. Thus, when viewed in a plane, the beaded rim 862 in this example is generally 'D' shaped and includes a sealing surface 864A extending away from the hinge 760 and a sealing surface 864B extending adjacent to and parallel to the hinge 760.

[0474] In this example, an alternative bead flange profile is provided. In this example, the sidewalls of the bead flange are generally straight and not inclined relative to the plane of valve baffle 852. Similarly, when viewed from the side, the sealing surface 864A in this example is straight; that is, the sealing surface 864 is a planar surface having a plane sloping downwards from the distal portion of baffle 862 toward hinge 760. Therefore, bead flange 862 is tapered like bead flange 762, but when viewed from the side, sealing surface 864A is straight and does not have curved or inclined areas. This enhances the seal provided between sealing surface 864A and the bend and reduces the likelihood of leakage paths forming. The bead flange 862 in this example is also more rigid, which helps prevent the baffle edge from rising and leaking at lower pressures due to the bending of baffle 852.

[0475] Figure 22 This is a cross-sectional view of the patient interface, which includes a soft seal 261 fixed to a rigid or more rigid housing component 262. The housing 262 includes a gas inlet 263 with an outwardly (or alternatively inwardly) extending annular housing collar 264 surrounding it. An annular mounting collar 265 is mounted to the frame 8 in a suitably shaped aperture by snap-fit ​​or fastening, or welded in place, and the mounting collar 265 preferably receives the annular housing collar 264 using a snap-fit ​​or fastening engagement. When the mask is assembled for use, the upper annular end 266 of the bend 29 is secured, for example, by snap-fit ​​or fastening into the inner diameter of the mounting collar 265 so that the bend is coupled to the annular mounting collar 265 (instead of the frame or housing). Alternatively, the seal-housing component may comprise a single-material seal component. The annular mounting collar 265 may be made of a different material and / or color than the frame 8. Further details of this patient interface are disclosed in WO 2015 / 057087, the entire contents of which are incorporated herein by reference.

[0476] Figure 22 The patient interface also includes or is configured to connect to connector 267, preferably via a snap-fit ​​connection, as shown. The outer surface 268 of connector 267 is configured to be received in a breathing tube (not shown) or a collar connector (also not shown) located at the patient end of the breathing tube. Figure 22The connector 267 shown is configured to sealably engage a breathing tube (or a collar terminating a breathing tube) using a friction fit. For this purpose, one or more walls of the engagement wall may be tapered. For example, the outer surface 268 of the connector 267 may have a narrower or smaller external dimension near the first end 268, and a wider or larger external dimension at a point between the first end 268 and the second end 269 of the connector 267. Alternatively, the opening (internal dimension) of the breathing tube may vary from having a relatively large dimension near its opening to having a smaller or narrower dimension at an axially inward position within the breathing tube, the narrower portion being the size and position relative to the wider portion. As will be understood, in cases where the breathing tube is provided with a collar termination, a tapering may be formed in the collar rather than in the breathing tube.

[0477] Figure 22 The problem with this arrangement is that the user may push connector 267 onto bend 29 in the opposite direction, for example, bringing end 269 closer to the patient interface and end 268 away from it. Due to the tapering walls and the fact that the internal dimensions of the connector are approximately the same as the external dimensions of bend 29, in this configuration, collar 267 can engage frictionally with bend 29. This is undesirable because the connection between connector 267 and bend 29 may be disrupted. Furthermore, it may be difficult to remove connector 267 from bend 29 or to remove the breathing tube (or its end collar) from connector 267. More specifically, supplying connector 267 to the breathing tube or engaging the breathing tube with said connector can apply pressure to connector 267, thereby tightening the fit between connector 267 and bend 29. This situation may be exacerbated when the breathing tube or the collar used for it is pushed too far toward the patient interface onto connector 267.

[0478] To address these issues, a new connector 270 has been designed, such as... Figures 23A to 25F As shown. Figures 23A to 23D Showing the connection to Figure 22 The connector 270 is similar to the bend in the pipe 29. Figures 24A to 24C Show Figures 23A to 23D The bend in the pipe, and Figures 25A to 25F Show Figures 23A to 23D The connector.

[0479] Connector 270 has a first end 271 and a second end 272. The first end 271 is configured to engage with a bend (such as, Figure 22The bend 29 shown may be a protruding collar, which would otherwise form a gas path with the inside of the patient interface or mask. For example, in a simpler arrangement, the bend may be omitted, and the connector may be coupled to a collar extending from the patient interface, which is integrally formed with or coupled to the patient interface, such as via a housing.

[0480] The outer surface of at least the wall forming connector 270 preferably tapers gradually along at least a portion of the wall's length, such that at least a portion of connector 270 closer to the first end 271 has a larger external dimension than a portion of connector 27 closer to the second end 272. This taper refers to the substantially cylindrical body forming connector 270, rather than a rib or protrusion 273 near the first end 271 of connector 270. Tapering is commonly used in tube connectors and is configured to engage with a breathing tube or a collar terminating such a tube, as will be apparent to those skilled in the art. Alternatively or additionally, a taper may be provided inside the breathing tube (or collar terminating the tube), the interior of which narrows from its opening. Tapering facilitates insertion of the second end 272 of connector 270 into the breathing tube, wherein a seal is formed on further insertion of the second end.

[0481] As in Figure 23D and Figure 25E As best seen in the image, the interior of connector 270 includes ribs 274 that engage one or more protrusions 275 on the bend connector 29a to form a snap-fit ​​or latching engagement. Generally, bend connector 29a is substantially the same as or similar to previously disclosed bend connectors herein; therefore, only the relevant features of bend connector 29a will be described. It should be noted that... Figure 23A The bent connector 29 shown includes a cover 276, which is in Figure 23D Multiple vent holes 277 are omitted to expose the contents. The cover 276 may be a filter to allow gas and / or moisture to pass through, or it may be solid and impermeable so as to block the vent holes 277 when the cover 276 is in place.

[0482] The interior of the connector 270, extending from a certain point toward the second end 272, is preferably sized to prevent the inner surface of the second end 272 of the connector 270 from engaging with the outer surface of the bend connector 29a if the user attempts to assemble the components incorrectly. In a preferred embodiment, this is achieved by making the internal dimension (generally the diameter) of the connector 270 larger than the external dimension of the bend connector 29a that engages with the connector 270, making it easy to understand, given the loose fit between them, that they are incorrectly assembled. Alternatively, the second end 272 of the connector 270 may have an internal dimension that prevents the bend connector 29a from being inserted therein, i.e., the second end is too narrow or includes a protrusion that acts as a stop.

[0483] The rib or protrusion 273 serves two functions. First, it provides a grip for the user's fingers, which can be used to remove the connector 270 from engagement with the bend connector 29a. Second, it acts as a mechanical stop to limit how far the breathing tube can be pushed onto the second end 272 of the connector 270.

[0484] Although the illustrated embodiment has a rib or protrusion 273 that arcs in a sinusoidal pattern around the outer circumference of the connector 270 near the first end 271, the rib or protrusion 273 can be formed in other ways. For example, it may extend only partially around the circumference or include multiple discrete elements, each of which extends partially around the circumference. Furthermore, as a complement or alternative to the arcuate portion, the protrusion or rib may be substantially linear and / or include linear portions.

[0485] For further reference Figures 26 to 31 Another embodiment of the bend assembly 902 includes a bend 922 and a sleeve (not shown), the bend and sleeve having a... Figures 14 to 19 The bend 722 and sleeve 710 have similar features. A rotating member 330 as described above can also be provided, but... Figures 26 to 31 It is not shown in the middle.

[0486] An anti-suffocation valve (AA valve) 950 is provided and mounted on a sleeve such that it at least partially obstructs the flow passage of the sleeve. The AA valve 950 has the same characteristics as... Figures 14 to 19 Similar features to valve 750. The bend assembly 902 functions similarly. Figures 10 to 13 The pipe bending assembly 302 and Figures 14 to 19 The bend in the tube assembly, and similarly directs gas away from the patient when the baffle 952 of the AA valve 950 descends to its closed position (i.e., a generally horizontal position) and closes the flow passage through the tube.

[0487] AA valve 950 includes a generally flat valve baffle 952, which is hingedly mounted on a baffle support 954, the baffle support being integrally formed with the valve baffle 952. In this example, with Figures 14 to 19 Compared to the valve baffle 752 shown, the valve baffle 952 and baffle support 954 are configured such that, when at rest, the baffle 952 is biased downwards so as to be inclined relative to an imaginary horizontal plane before the sleeve is assembled onto the bend 922, that is, inclined downwards relative to the plane below the baffle support 954. When the valve 950 is installed in the bend 922 in use and the sleeve is in place, the baffle 952 is horizontal, wherein the lower surface of the plane of the baffle 952 is flush with and parallel to the upper surface sealing surface of the sleeve, for example, as shown. Figure 14 As shown.

[0488] During assembly, as the sleeve is fully assembled onto the bend 922, the sleeve moves the downwardly tilted valve flap 952 upward to a generally horizontal position. When the valve flap 952 is stationary in the generally horizontal position, the flap 952 attempts to pivot downward against the sleeve; that is, the flap 952 is biased downward away from the vertical direction, thereby helping to maintain the flap 952 in a horizontal orientation, where the flow passage through the sleeve is closed, while the air vent passage in the bend 922 is open. This biased flap 952 helps ensure that the user of the bend can still breathe through the air vent passage in the bend 922 when breathing gas is not being delivered through the flow passage in the sleeve.

[0489] The degree of offset created by the initially downward-tilted baffle 952 can be configured by the following: the thickness of the hinge 960 between the support 954 and the baffle 952, and the size of the angle of the baffle 952 relative to an imaginary horizontal plane (parallel to the lower surface of the plane of the support 954) when the baffle 952 is stationary before assembly with the sleeve. If the hinge thickness is too large, the baffle 952 will not be able to flex easily enough to pivot about the hinge 960 as described above. If the hinge thickness is too thin, the baffle 952 may be unstable because it flexes, deforms, and vibrates too much in the vertical and / or horizontal position to perform an effective seal.

[0490] In this example, valve 950 is provided with additional features that can also be used with other examples of valves 350 and 750 described herein. One such feature is that, in this example, the sealing bead edge 964 extends around the top surface of valve baffle 952 to form a 'D'-shaped seal, as is the bead edge 764 of valve baffle 752. However, at a portion of the bead edge 964 adjacent to support 954, the bead edge 964 includes a linear bead edge portion 964a with an increased surface area, which abuts against the vertical front surface 954a of support 954 for sealing when baffle 952 is in a vertical orientation. The portion 964a includes an elliptical planar sealing surface that extends from one side of baffle 952 to the other adjacent to hinge 960. The width and length of the sealing surface 964a closely correspond to, or are preferably equal to, the height and width of the front surface 954a of the support block 954, such that when the baffle 952 is in the vertical position, the sealing surface 964a substantially matches and abuts against the front surface 954a in size and shape, thus creating a seal. This produces an improved seal between the baffle 952 and the portion of the support 954 that contacts the support.

[0491] The edge of the elliptical sealing surface 964a includes an inclined transition wall 964b, at which the surface 964a intersects with the upper planar surface 972 of the valve baffle 952. The upper planar surface 972 is defined as a recessed planar region defined by the sealing bead edge 964. The thickness of the wall 964b can be configured to control the stiffness of the baffle 952; that is, the wall 964b acts as a reinforcing rib or reinforcing member. The wall 964b can help prevent the valve baffle 952 from ballooning or otherwise flexing and deforming under pressure during use, which would otherwise make the baffle 952 (especially the upper planar surface 972) too thin to withstand the pressure generated during use.

[0492] Similarly, and specifically referring to FIG. 28c, the lower side of the valve baffle 952 adjacent to the hinge 960 may include a notch 965, which is configured to allow the valve baffle 952 to flex with a desired amount adjacent to the hinge 960. Some of the flex of the valve baffle 952 can be used to allow the baffle 952 to deform sufficiently to achieve the best possible seal against the sealing surfaces of the bend 922 and the sleeve. In this example, the notch 965 is rectangular and is defined directly below the upper sealing surface 964a.

[0493] The dimensions and thicknesses of the valve baffle 952 and the support 954 can be configured as individual parameters, and / or relative to each other, to ensure that the valve baffle 952 has the desired characteristics to achieve optimal sealing in both horizontal and vertical positions, and also appropriately responds to pressure changes to effectively move from the horizontal position to the vertical position and vice versa. See also... Figure 31The figure shows some exemplary, not limiting, dimensions in one embodiment of valve 950.

[0494] Valve 950 may have the following characteristics, each of which may be provided as a separate feature or in combination with another feature or some other features: a) Before assembly between the bend and the sleeve, the angle between the baffle 952 and the imaginary horizontal plane (in particular the angle between the lower surface of the baffle 952 and the imaginary horizontal plane) can be tilted between 0° and 90°, and preferably between 0.5° and 75°, more preferably between 5° and 60°, even more preferably between 5° and 45°, and in a preferred embodiment between 10° and 40°.

[0495] b) When, for example, according to Figure 31 When viewed from the side, the thickness B of the hinge 960 can be between 0.05 mm and 1.0 mm, preferably between 0.1 mm and 0.75 mm, more preferably between 0.1 mm and 0.5 mm, even more preferably between 0.15 mm and 0.4 mm, and in a preferred embodiment is 0.25 mm.

[0496] c) When viewed from the side, the thickness A of the support 954 can be between 1 mm and 10 mm, preferably between 1 mm and 7.5 mm, more preferably between 1 mm and 5 mm, and in a preferred embodiment is 4.75 mm.

[0497] d) The thickness E of the valve baffle 952 in the region of the upper planar surface 972 between the sealing bead edges 964 can be between 0.1 mm and 2 mm, preferably between 0.5 mm and 1.5 mm, more preferably between 0.5 mm and 1 mm, and in a preferred embodiment is 0.75 mm.

[0498] e) When the cross-section is viewed from the side, the thickness D of the inclined wall 964b can be between 0.1 mm and 1.5 mm, preferably between 0.2 mm and 1 mm, more preferably between 0.2 mm and 0.75 mm, even more preferably between 0.3 mm and 0.6 mm, and in a preferred embodiment it is 0.53 mm.

[0499] f) When the cross-section is viewed from the side, the thickness C of the bead edge region 964a above the notch 965 can be between 0.1 mm and 1 mm, preferably between 0.1 mm and 0.75 mm, more preferably between 0.1 mm and 0.5 mm, and in a preferred embodiment is 0.3 mm.

[0500] g) When viewed in a plane, the width F of the bead edge region 964a in a direction away from the hinge axis and away from the support 954 can be between 2 mm and 6 mm, preferably between 2 mm and 5 mm, more preferably between 3 mm and 4 mm, and in a preferred embodiment is 3.89 mm.

[0501] h) In the direction extending vertically from the hinge 960 to the apex of the valve baffle 952, the length of the valve baffle 952 may be between 10 mm and 25 mm, preferably between 10 mm and 20 mm, more preferably between 12 mm and 18 mm, and in a preferred embodiment is about 15.5 mm.

[0502] i) When viewed from the side, the bead edge 964 preferably tapers towards the hinge 960, so that it is relatively thick at the distal end of the hinge 960 and relatively thin adjacent to the hinge 960. The bead edge 964 (particularly the plane of the upper top surface of the bead edge 964) may form an angle between 0° and 45° with respect to the lower plane of the baffle 952, preferably between 0° and 30°, more preferably between 1° and 15°, and in a preferred embodiment, an angle of about 4°. The larger the angle, the more the bead edge extends into the flow path of the bend assembly. However, the smaller the angle, the more likely the baffle is to undesirably stick in the vertical orientation.

[0503] j) When viewed from above, Figures 26 to 31 In some examples, the baffle 964 is generally semi-circular or horseshoe-shaped. However, in other embodiments, the baffle can be any other desired shape and, when viewed in a plane, can be, for example, generally square, rectangular, triangular, circular, or omega-shaped.

[0504] According to the present invention, the following ratios of the characteristics of valve 950 can be changed as follows: k) The ratio of the thickness of the support block 954 to the thickness of the hinge 960 can be between 5:1 and 30:1, more preferably between 10:1 and 25:1, even more preferably between 15:1 and 25:1, and in a preferred embodiment is 19:1.

[0505] l) The ratio of the thickness of the valve baffle 952 to the thickness of the hinge 960 in the region of the upper planar surface 972 between the bead edges: can be between 1:1 and 10:1, more preferably 1:1 to 8:1, more preferably 2:1 to 5:1, and in a preferred embodiment is 3:1.

[0506] The ratio of the thickness of the valve baffle 952 in the region of the upper planar surface 972 between the bead edges to the thickness of the bead edge region 964a above the notch 965 can be between 1:1 and 10:1, more preferably 1:1 to 8:1, more preferably 2:1 to 5:1, and in a preferred embodiment 2.5:1.

[0507] The ratio of the thickness of the valve baffle 952 to the thickness of the inclined wall 964b in the region of the upper planar surface 972 between the bead edges can be between 1:1 and 10:1, more preferably 1:1 to 5:1, even more preferably 1:1 to 2:1, and in a preferred embodiment 1.4:1.

[0508] o) The ratio of the thickness of the valve baffle 952 in the region of the upper planar surface 972 between the bead edges to the thickness of the bead edge region 964a above the notch 965 can be between 1:1 and 10:1, more preferably 1:1 to 5:1, more preferably 2:1 to 3:1, and in a preferred embodiment 2.5:1.

[0509] p) The ratio of the thickness of the inclined wall 964b to the thickness of the bead edge region 964a above the notch 965 can be between 1:1 and 10:1, more preferably 1:1 to 5:1, even more preferably 1:1 to 2:1, and in a preferred embodiment 1.75:1.

[0510] q) The ratio of the thickness of the support block 954 to the width of the bead edge region 964a can be between 1:1 and 10:1, more preferably 1:1 to 5:1, even more preferably 1:1 to 2:1, and in a preferred embodiment it is 1.2:1.

[0511] r) The ratio of the width of the bead edge region 964a to the thickness of the bead edge region 964a above the notch 965 can be between 1:1 and 30:1, more preferably 1:1 to 20:1, even more preferably 1:1 to 15:1, and in a preferred embodiment 13:1.

[0512] Circular deflection airflow

[0513] To understand this disclosure in more detail, please refer first to... Figure 32 The figure illustrates a breathing circuit according to at least one embodiment, the breathing circuit including a breathing mask.

[0514] Figure 32This is a schematic diagram of a positive airway pressure (CPAP) system in the form of a continuous positive airway pressure (CPAP) system 1010, which provides a heated and humidified airflow to a user U via an interface 1110 worn by the user and connected to the CPAP system 1010 by a conduit or tube 1012. A humidification chamber 1014 has a heat-conducting substrate in contact with a heating plate 1016 of a humidifier 1017 to humidify the airflow. A conduit 1012 is connected to an outlet 1013 of the humidification chamber 1014 to deliver the humidified air to the user interface 1110. The humidifier 1017 includes a controller 1018, such as, but not limited to, a microprocessor-based controller that executes computer software commands stored in an associated memory. The controller 1018 receives input commands from multiple sources, including a user input interface 1019 such as a turntable or touchscreen, enabling the setting of predetermined values ​​for the humidity, temperature, or other characteristics of the humidified air supplied to the user U. The controller 1018 may also receive input from one or more other sources, such as temperature and / or flow rate sensors 1020 and 1021, which are connected via connector 1022 to communicate with the controller 1018 and / or the heating plate temperature sensor 1023. In response to a selected humidity or temperature value, the controller 1019 determines when and / or to what level the heating plate 1016 should be energized to properly heat the water contained in the humidification chamber 1014.

[0515] When a certain volume of water in the chamber is heated, water vapor begins to fill the volume of the chamber above the water surface. The water vapor exits the humidification chamber's outlet 1013 along with airflow supplied from a source 1025 (such as a blower 1027) and entering the humidification chamber 1030 through inlet 1026. The blower 1027 may be a variable-speed fan or may include a variable-pressure regulator. The blower 1027 draws air through inlet 1028. The blower may be controlled, for example, by a controller 1029 or a controller 1018. The controller 1018 or 1029 may control the blower speed, regulated pressure, etc., according to any suitable criteria. For example, the controller 1029 may respond to inputs from the controller 1018 and user-defined values ​​(e.g., preset values) for pressure and / or fan speed that can be set using a user interface 1030 (e.g., a rotary table).

[0516] The conduit 1012 may include a heater, such as a heating wire, to heat the walls of the conduit to reduce condensation of humidifying gas inside the conduit.

[0517] Regardless of whether humidification is used, the respiratory masks and components disclosed herein can be used in such CPAP systems as described above, or alternatively in other forms of respiratory systems, such as VPAP (Variable Positive Airway Pressure) systems, BiPAP (Biphasic Positive Airway Pressure) systems, or systems with ventilators, and are generally described herein only by way of example in conjunction with CPAP therapy.

[0518] The deflection ventilation system used to expel exhausted air from the breathing mask will be described in more detail below. The ventilation system typically provides a path through which the user's exhaled air can be expelled into the atmosphere.

[0519] III. The two-part spherical joint socket and the deflection gas in the connecting shell

[0520] In various embodiments, the deflection ventilation system may be incorporated into a connecting housing that engages with a housing for sealing elements such as gaskets. The connecting housing engages directly with the socket of a truncated ball joint connector, thus forming an integral (one-piece) structure. The integral structure can be disassembled into at least two parts (e.g., separate sockets and connecting housing) to facilitate cleaning of the deflection ventilation system. When used in a breathing mask, the integral structure is configured to deliver inhaled gas received from the truncated ball joint connector to the user of the breathing mask. Because the integral structure incorporates the deflection ventilation system, it is capable of not only supplying inhaled gas to the user but also removing exhaled gas from the user. The configuration of the integral structure improves the overall compactness of the breathing mask.

[0521] A. The assembly obtained through the groove in the bearing socket

[0522] First refer to Figures 33A to 33C In at least one embodiment, a kit 1200 for a breathing mask is disclosed. It should be understood that assemblies of one, some, or all of the components of kit 1200 are within the scope of this disclosure, and such assemblies and breathing systems including such assemblies should be considered embodiments of this disclosure.

[0523] The kit 1200 includes a connecting housing 1202 that is placed on the patient's face during use. The connecting housing 1202 includes a first end portion 1204 ( Figure 33A and Figure 33C The first end portion is configured to engage a buffer housing for contacting the user's face. Figures 33A to 33C The connecting housing has been omitted from the drawings to simplify the illustrations. Suitable connecting housings are shown and described, for example, in U.S. Patent Application No. 62 / 041,262 and U.S. Patent Application No. 62 / 096,481, which are previously incorporated herein by reference. It should be understood that in some embodiments, the connecting housing may be included in kit 1200, an assembly of said kit, and a breathing system including such an assembly.

[0524] The connecting housing 1202 also includes a connecting ring 1206 opposite to the first end portion 1204. The connecting ring 1206 includes a first connecting housing protrusion 1208. Figure 33A and Figure 33B ) and the second connecting housing protrusion 1210 ( Figure 33A and Figure 33B The first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 are each generally arcuate and extend away from the first end portion 1204. In this example, the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 are opposite to each other around the connecting ring 1206. Each of the first and second connecting housing protrusions includes an array of at least one hole 1212 extending along at least a portion of the respective arc. Figure 33A The array of holes is configured to deliver exhaled gas from the user into the surrounding atmosphere during use. These holes 1212 can be formed during the molding of the connecting ring 1206, or can be drilled out after molding (e.g., using a laser). Many hole array configurations are contemplated and are within the scope of this disclosure. For example, a single linear array and a dual linear array are contemplated. The holes 1212 can be circular or non-circular. See, for example, [reference needed]. Figures 39A to 39D Other instances of the array are shown. And although Figures 39A to 39D Involving and Figures 33A to 33C The embodiments shown are different from those of the present invention, but it should be understood that the exemplary aperture arrays shown can be incorporated into the embodiments of the present invention.

[0525] exist Figures 33A to 33C In an exemplary embodiment, the connecting housing 1202 includes two connecting housing protrusions 1208 and 1210. However, it should be understood that the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 may be elements in more connecting housing protrusions in other configurations. For example, the connecting housing 1202 may include three, four, five or more connecting housing protrusions.

[0526] The first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 define a generally arcuate first connecting housing recess 1214 between them. Figure 33A ) and the generally arc-shaped second connecting housing recess 1216 ( Figure 33A In this exemplary embodiment, the arc length of the first connecting housing recess 1214 is smaller than the arc length of the second connecting housing recess 1216. The advantages of this configuration are discussed below. Figures 33A to 33CIn an exemplary embodiment, the connecting housing 1202 includes two connecting housing recesses 1214 and 1216. However, it should also be understood that the first connecting housing recess 1214 and the second connecting housing recess 1216 may be elements in more connecting housing recesses in other configurations. For example, the connecting housing 1202 may include three, four, five or more connecting housing recesses.

[0527] Kit 1200 also includes an annular socket 1218 configured to deliver inhaled gas from a gas supply to the connecting housing 1202 via a central hole in the socket 1218. The gas supply may be, for example, a rotary connector (not shown) configured to deliver inhaled gas to a user. The rotary connector may include, for example, a generally tubular first end and a truncated ball joint at a second end opposite the first end, the truncation defining a ball joint opening configured to allow inhaled gas to pass through it. Other configurations are contemplated, such as a rotary bend configured to rotate on a single axis instead of a truncated ball joint. Other example rotary connectors are shown and described below, and these depictions and descriptions are incorporated herein by reference. The socket 1218 is configured to receive the truncated ball joint in use. It should be understood that in some embodiments, the rotary connector may be included in kit 1200, an assembly of the kit, and a breathing system including such an assembly.

[0528] The kit 1200 may also optionally include a frame 1228 that is mounted on the connecting housing 1202 during use. In at least one embodiment, the frame 1228 includes a frame housing 1230 ( Figure 33A and Figure 33B The frame housing includes a frame opening 1232 having a generally annular periphery. Figure 33A and Figure 33C The frame housing 1230 is optionally molded as a single piece onto the socket 1218. The socket 1218 may optionally be permanently mounted in the frame housing 1230, for example, by gluing, press-fitting, welding, or brazing. In some embodiments, the socket 1218 may be removably mounted in the frame housing 1230, for example, by a snap-fit ​​connection.

[0529] Referring again to the socket 1218, the socket 1218 includes a generally arc-shaped first socket protrusion 1220 ( Figure 33A and Figure 33B ) and the generally arc-shaped second bearing protrusion 1222 ( Figure 33A and Figure 33B The arc length of the first bearing protrusion 1220 can be less than the arc length of the second bearing protrusion 1222.

[0530] The first bearing protrusion 1220 and the second bearing protrusion 1222 define a generally arcuate first bearing groove 1224 between them. Figures 33A to 33C ) and the generally arc-shaped second bearing groove 1226 ( Figure 33A and Figure 33B In this example, the outer periphery of the socket 1218 fully and continuously engages with the inner periphery of the frame opening 1232, and the socket 1218 includes socket grooves 1224 and 1226 within its outer periphery, which are used to engage with the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210. Furthermore, in this example, the first socket groove 1224 is opposite to the second socket groove 1226. In the illustrated example, the socket protrusions 1220 and 1222 are located at the top and bottom of the socket 1218. This configuration advantageously allows the socket grooves to be positioned on the sides of the socket 1218, which is desirable for reasons discussed below.

[0531] The socket 1218 is configured to removably engage with the connecting housing 1202 as an integral structure, such that, upon engagement, the first socket protrusion 1220 engages with the first connecting housing recess 1214, the second socket protrusion 1222 engages with the second connecting housing recess 1216, the first connecting housing protrusion 1208 passes through the frame opening 1232 and engages with the first socket groove 1224, and the second connecting housing protrusion 1210 passes through the frame opening 1232 and engages with the second socket groove 1226. Intake gas flows out from the rotary connector and through the central hole of the socket 1218 to the connecting housing 1202. Exhaled air flows out from the connecting housing 1202 and passes through a first space between a first region radially inward from the first recess groove 1224 of the first connecting housing protrusion 1208 and the recess 1218, and through a second space between a second region radially inward from the second recess groove 1226 of the second connecting housing protrusion 1210 and the recess 1218. From the first and second spaces, exhaled air is delivered to the surrounding atmosphere via an array of at least one hole 1212 in each of the first and second connecting housing protrusions 1208 and 1210. In this way, when in use, inhaled air is delivered to the breathing mask via the integral structure and exhaled air is delivered out of the breathing mask.

[0532] exist Figures 33A to 33CIn an exemplary embodiment, the socket 1218 includes two socket protrusions 1220 and 1222 and two socket grooves 1224 and 1226. It should also be understood that the first socket protrusion 1220 and the second socket protrusion 1222 may be elements of a plurality of socket protrusions in other configurations. Similarly, the first socket groove 1224 and the second socket groove 1226 may be elements of a plurality of socket grooves in other configurations. For example, the socket 1218 may include three, four, five, or more socket protrusions. And the socket 1218 may include three, four, five, or more socket grooves. Typically, the number of socket protrusions and socket grooves can be selected to suitably engage the number of connecting housing protrusions and connecting housing recesses of the connecting housing 1202.

[0533] As mentioned above, in Figures 33A to 33C In this example, the arc length of the first connecting housing recess 1214 is less than the arc length of the second connecting housing recess 1216; and similarly, the arc length of the first bearing protrusion 1220 is less than the arc length of the second bearing protrusion 1222. With this configuration, the first bearing protrusion 1220 engages with the first connecting housing recess 1214, and the second bearing protrusion 1222 engages with the second connecting housing recess 1216. However, the first bearing protrusion 1220 does not engage with the second connecting housing recess 1216, and the second bearing protrusion 1222 does not engage with the first connecting housing recess 1214. In other words, the bearing 1218 will removably engage with the connecting housing 1202 in only one direction. This configuration can advantageously facilitate engagement by an inexperienced user. However, it should be understood that the arc length can be selected so that the bearing 1218 engages with the connecting housing 1202 in any or multiple directions, if desired. For example, the arc lengths can be equal.

[0534] Next, refer to Figure 34A and Figure 34B The first connecting housing protrusion 1208 ( Figure 34A ) and the second connecting housing protrusion 1210 ( Figure 34A and Figure 34B Each of the above may include a generally L-shaped end portion 1302 at the region furthest from the first end portion 1204. The first bearing protrusion 1220 ( Figure 34A and Figure 34B The second and second bearing protrusions 1222 (not shown) each have a groove in the first bearing groove (in Figure 34A and Figure 34B (not shown in the image) and the second bearing groove (in the image) Figure 34A and Figure 34B(Not shown in the image) Adjacent areas include generally L-shaped sides 1304. The generally L-shaped end portions 1302 of the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 can be configured to seal with the generally L-shaped sides 1304 of the first socket protrusion 1220 and the second socket protrusion 1222. This configuration can be advantageous because it effectively forms two sealing surfaces between the socket 1218 and the connecting housing 1202 when they are integrally joined. It has been found that this configuration is less prone to leakage and tolerance issues compared to other sealing arrangements. (See below for reference.) Figure 36 Alternative joining arrangements are shown and discussed. These alternative joining arrangements also apply to… Figure 33A and Figure 33B The embodiments described herein, along with the discussion and related drawings, are incorporated herein by reference.

[0535] B. The assembly obtained through the gap between the frame and the bearing socket.

[0536] Next, refer to Figures 35A to 35C In at least one embodiment, another kit 1200 for a breathing mask is disclosed. It should be understood that assemblies of one, some, or all of the components of kit 1200 are within the scope of this disclosure, and such assemblies and breathing systems including such assemblies should be considered embodiments of this disclosure.

[0537] Reference Figures 33A to 33C The described kit is similar to 1200. Figures 35A to 35C The kit 1200 for a breathing mask includes a connecting housing 1202 that is placed on the patient's face during use. The kit 1200 also includes a socket 1218 and a frame 1228. Figure 35A and Figure 35B ). refer to Figures 33A to 33C Discussion of the connecting housing 1202, frame 1228, and socket 1218 is incorporated herein by reference. Kit 1200 may also include a rotary connector (not shown) configured to deliver inhaled gas to the user, and discussion of the rotary connection is also incorporated herein by reference.

[0538] Figures 33A to 33C Implementation examples and Figures 35A to 35C The difference between the embodiments is the configuration of the socket 1218. Figures 33A to 33C In one embodiment, the outer periphery of the socket 1218 is completely and continuously engaged with the frame opening 1232, and the socket 1218 includes socket grooves 1224 and 1226 within its outer periphery, the socket grooves being used to engage with the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210. Figures 35A to 35CIn this embodiment, the outer periphery of the socket 1218 is not completely and continuously engaged with the frame opening 1232. Instead, the outer periphery is not annular like the frame opening 1232, resulting in a space between the outer periphery of the socket 1218 and the frame opening 1232, including a first frame gap 1402 (Figure 35 and...). Figure 35B ) and the gap between the second frame 1404 ( Figure 35A ).

[0539] Similarly, as referenced Figures 33A to 33C (and refer to these figures and) Figures 35A to 35C Similar to the kit 1200 described above, frame 1228 is configured to removably engage with connecting housing 1202 as an integral structure, except that, when engaged, the first recessed protrusion 1220 engages with the first connecting housing recess 1214, the second recessed protrusion 1222 engages with the second connecting housing recess, the first connecting housing protrusion 1208 passes through frame opening 1232 and engages with the first frame gap 1402, and the second connecting housing protrusion 1210 passes through frame opening 1232 and engages with the second frame gap 1404.

[0540] Inhaled gas flows out from the rotary connector and through the central hole of the socket 1218 to the connecting housing 1202. Exhaled gas flows out from the connecting housing 1202 and through a first space between the first connecting housing protrusion 1208 and a first region of the socket 1218 radially inward from the first frame gap 1402, and through a second space between the second connecting housing protrusion 1210 and a second region of the socket 1218 radially inward from the second frame gap 1404. From the first space and the second space, exhaled gas flows through an array of at least one hole in each of the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 (in... Figure 33A As shown in the figure, while Figures 35A to 35C (Not shown) is transmitted to the surrounding atmosphere. Therefore, in both embodiments, when in use, inhaled gas is transmitted to the breathing mask via the integral structure and exhaled gas is transmitted out of the breathing mask.

[0541] Next, refer to Figure 36 The first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 may each include a generally straight end portion 1502 in the region furthest from the first end portion 1204. The first bearing protrusion 1220 and the second bearing protrusion 1222 may each have an end portion 1502 in relation to the first bearing groove 1224 and the second bearing groove 1226 (in Figure 36The area adjacent to the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 includes a generally straight side portion 1504. The generally straight end portions 1502 of the first connecting housing protrusion 1208 and the second connecting housing protrusion 1210 can be configured to be adjacent to the first bearing protrusion 1220 (not shown in the image). Figure 36 The generally straight side 1504 of the second and third recessed protrusions 1222 (not shown) is sealed, for example, using a friction fit seal. In alternative or improved configurations, supplementary seals, such as gaskets, O-rings, or lip seals, may be provided between the sealing surfaces.

[0542] The above is for reference only. Figure 34A and Figure 34B Another alternative joining arrangement (incorporating an L-shaped fitting) is shown and discussed. This alternative joining is also applicable to… Figures 35A to 35C The embodiments described herein, along with the discussion and related drawings, are incorporated herein by reference.

[0543] IV. Deflected airflow in a spherical joint socket with a concave flow path

[0544] In various embodiments, the deflection ventilation system may be incorporated into a socket of the truncated ball joint connector. The socket includes an area for easy cleaning of the deflection ventilation system. When used in a breathing mask, the socket is configured to deliver inhaled gas received from the truncated ball joint connector to the user of the breathing mask. Because the socket incorporates the deflection ventilation system, it can not only supply inhaled gas to the user but also remove exhaled gas from the user. The socket configuration improves the overall compactness of the breathing mask. Certain embodiments have also been found to advantageously reduce noise generated by the breathing mask during use.

[0545] Next, refer to Figures 37A to 37E as well as Figures 38A to 38E In at least one embodiment, a kit 1600 for a breathing mask is disclosed. It should be understood that assemblies of one, some, or all of the components of kit 1600 are within the scope of this disclosure, and such assemblies and breathing systems including such assemblies should be considered embodiments of this disclosure.

[0546] In some embodiments, kit 1600 includes a rotary connector 1602 configured to deliver inhaled gas to a user. Figure 37A , Figure 37C , Figure 37E , Figure 38A , Figure 38B , Figure 38C and Figure 38E The rotary connector 1602 includes a generally tubular first end 1604. Figure 37A , Figure 37C , Figure 37E , Figure 38A and Figure 38B) and the truncated ball joint 1606 at the second end opposite to the first end 1604 ( Figure 37A , Figure 37C , Figure 37E , Figure 38A , Figure 38B , Figure 38E The truncated section defines a spherical connector opening 1608 configured to allow inhaled gas to pass through it. Figure 37A , Figure 37C , Figure 37E , Figure 38A , Figure 38B , Figure 38E ).

[0547] Kit 1600 also includes a connection housing 1610 that is placed on the user's face during use. Figure 37E and Figure 38E The connecting housing 1610 includes a connecting housing opening 1612. Figure 37E and Figure 38E The connection housing opening is configured to receive inhaled gas from the rotary connector 1602 and exhaled gas from the user during use. The connection housing 1610 also includes a buffer end portion (not shown) opposite to the connection housing opening 1612, which is configured to engage a buffer housing for contact with the user's face.

[0548] Kit 1600 also includes a socket 1616. The socket 1616 includes a connecting housing engagement area 1620. Figure 37A , Figure 37B , Figure 38A and Figure 38D The connecting housing engagement area 1620 generally circumferentially surrounds the first end 1622 of the bearing socket 1616. Figure 37A , Figure 37B , Figure 38A and Figure 38D The connecting housing engagement region 1620 engages with the connecting housing opening 1612 during use and is configured to receive exhaled gas from the connecting housing opening.

[0549] The socket 1616 is hollow, so that the socket includes a closed internal region 1618. Figures 37A to 37E , Figure 38A , Figure 38B , Figure 38D and Figure 38E ) or hole. The enclosed internal region 1618 includes the ball joint engagement region 1624 ( Figure 37A , Figure 37B , Figure 37D , Figure 37E , Figure 38A , Figure 38B , Figure 38C , Figure 38D and Figure 38E The spherical joint mating area 1624 generally circumferentially surrounds the second end 1626 of the socket 1616 opposite to the first end 1622. Figure 37A , Figure 37B , Figure 38A and Figure 38D The ball joint engagement region 1624 engages with the truncated ball joint 1606 of the rotary connector 1602 during use and is configured to receive intake gas from the truncated ball joint. In the example figure, the diameter of the ball joint engagement region 1624 is smaller than the diameter of the connection housing engagement region 1620.

[0550] The enclosed internal region 618 also has a generally arc-shaped first load-bearing region 1628. Figure 37A , Figure 37B , Figure 37D , Figure 37E , Figure 38D ) and the generally arc-shaped second load-bearing area 1630 ( Figure 37D , Figure 38D Each of the first and second bearing regions extends from the ball joint engagement area 1624 toward the connecting housing engagement area 1620 and, in use, engages with the truncated ball joint 1606 of the rotary connector 1602. That is, the generally arcuate first bearing region 1628 and second bearing region 1630 engage with opposite sides of the truncated ball joint 1606. Therefore, a recessed area is formed circumferentially along the inner surface of the socket 1616 between the generally arcuate first bearing region 1628 and second bearing region 1630. The recessed area provides a shallow gap or void between the ball joint engagement area 1624 and the truncated ball joint 1606, which can be easily wiped and cleaned by the user. The bearing regions 1628 and 1630 are sized and configured to prevent the truncated ball joint 1606 from falling into the socket 1616. Figures 37A to 37E and Figures 38A to 38E In an exemplary embodiment, the socket 1616 includes two support regions 1628 and 1630. It should be understood that the first support region 1628 and the second support region 1630 can be elements among more support regions in other configurations. For example, the socket 1616 may include three, four, five, or more support regions. In one embodiment including three support regions, the first support region 1628, the second support region 1630, and an additional support region may be located at or near the 2 o'clock, 6 o'clock, and 10 o'clock positions, wherein the 6 o'clock position defines the bottom of the socket 1616.

[0551] The first bearing area 1628 and the second bearing area 1630 define a generally arc-shaped first exhalation area 1632 between them. Figure 37A , Figure 37B , Figure 37E , Figure 38A and Figure 38E ) and the generally arc-shaped second expiratory zone 1634 ( Figure 37A , Figure 37B , Figure 37E , Figure 38A and Figure 38E In some configurations, a generally arcuate first breathing region 1632 and a generally arcuate second breathing region 1634 may be positioned in a recessed region between a generally arcuate first support region 1628 and a generally arcuate second support region 1630. Flow paths to the first breathing region 1632 and the second breathing region 1634 may be defined by the generally arcuate first support region 1628 and the second support region 1630, the inner surface of the recess 1616, and the outer surface of the truncated spherical connector 1606. Each of the first exhalation region 1632 and the second exhalation region 1634 includes an array of at least one orifice 1636. Figures 39A to 39D The array of holes is configured to allow exhaled gas to pass through it and reach the surrounding atmosphere outside the socket 1616. The first exhalation region 1632 and the second exhalation region 1634 are discontinuous, that is, separated by the bearing regions 1628 and 1630. However, in some embodiments, the distance between the first exhalation region 1632 and the second exhalation region 1634 can be represented by a diameter, such as a straight line traveling from a point on the arc length of the first exhalation region 1632 to a corresponding point on the arc length of the second exhalation region 1634, the line passing through the extreme center of the enclosed inner region 1618. In the example shown, the diameter between the first exhalation region 1632 and the second exhalation region 1634 is greater than the diameter of the spherical joint engagement region 1624 and less than or equal to the diameter of the connecting housing engagement region 1620. Also in the example shown, the bearing regions 1628 and 1630 are located at the top and bottom of the socket 1616, respectively. This configuration advantageously allows the exhalation zones 1632, 1634 to be positioned on the side of the socket 1616, which may be desirable because, when the breathing mask incorporating the features of kit 1600 is in use, the configuration will direct the exhalation airflow away from the user's bed partner and the user's face.

[0552] It should be understood that the first exhalation region 1632 and the second exhalation region 1634 can be elements among more exhalation regions in other configurations. For example, the enclosed internal region 1618 may include three, four, or more exhalation regions. For example, in one embodiment including three exhalation regions, the first exhalation region 1632, the second exhalation region 1634, and an additional exhalation region may be located at or near the 12 o'clock, 4-5 o'clock, and 7-8 o'clock positions, wherein the 12 o'clock position defines the top of the recess 1616.

[0553] This configuration is advantageous for several reasons. The support regions 1628 and 1630 provide structure and support to the recess 1616. Furthermore, the exhalation regions 1632 and 1634 are recessed from the support regions 1628 and 1630, thereby allowing for improved ease of cleaning.

[0554] Furthermore, in the example shown, the arc length of the first exhalation region 1632 and the arc length of the second exhalation region 1634 are greater than the arc length of the first bearing region 1628 and the arc length of the second bearing region 1630.

[0555] Figures 39A to 39D An exemplary configuration of an array of at least one aperture 1636 in the exhalation regions 1632, 1634 is shown. Figure 39A A single array of holes 1636 is shown. This configuration can be advantageous because it provides a minimal axial arrangement of holes 1636. Figure 39B Two arrays of aperture 1636 are shown. This configuration can be advantageous because it allows more apertures 1636 to be located within a given arc length. Figure 39C Two arrays of orifices 1636 with an interlaced configuration are shown. The interlacing increases the distance between the orifices 1636 in the array. This configuration can improve air jetting and reduce noise because it separates the flow better. This configuration is also advantageous because it allows more orifices 1636 to be in a given arc length for a given distance between the orifices 1636. Figure 39D The elongated orifices 1636 can be advantageous because they provide a larger ventilation area in a compact arrangement. The elongated orifices 1636 can be spaced apart to avoid entrainment between the vents 1636 while still providing sufficient exhaust capacity. In other words, fewer orifices 1636 can be arranged with greater spacing because the increased area along the main (longitudinal) axis compensates for the reduced number of orifices 1636.

[0556] Kit 1600 may also optionally include frame 1638 which is mounted on connecting housing 1610 during use. Figure 37C , Figure 37E , Figure 38B , Figure 38E Frame 1638 may include a frame housing having a frame opening with a generally annular periphery. A socket 1616 is disposed within the frame opening. The frame housing may optionally be permanently joined to the socket 1616, for example, by molding, gluing, brazing, etc. The socket 1616 may also be removably joined, for example, by a snap-fit ​​engagement.

[0557] Figures 37A to 37E and Figures 38A to 38E The difference between the embodiments lies in the configuration of the internal contour of the truncated ball joint 1606. Figures 37A to 37EIn the embodiments, the internal contour of the truncated ball joint 1606 generally follows the corresponding external contour of the truncated ball joint 1606. See below for reference. Figure 37E As shown and discussed in more detail, in this "expansion bend" configuration, the incoming (draw-in) gas can expand and / or separate at the outlet of the truncated spherical joint 1606, thereby generating turbulence. In contrast, in Figures 38A to 38E In one embodiment, the rotary connector 1602 has an interior length with a continuous cylindrical or continuously tapering cylindrical profile, the length of which includes a second end, the entire truncated ball joint 1606, and a region extending towards the first end 1604 directly adjacent to the truncated ball joint 1606. A continuously tapering cylindrical profile can be advantageous because it allows for simplified tooling operations during manufacturing.

[0558] Figures 37A to 37E and Figures 38A to 38E Another difference between the embodiments lies in the position of the rotary connector 1602 within the socket 1616. Figures 37A to 37E In the embodiments, the rotary connector 1602 and the socket 1616 are configured such that when the truncated ball joint 1606 of the rotary connector 1602 is in the middle position within the ball joint engagement region 1628 of the socket 1616, the end of the truncated ball joint 1606 is substantially aligned with the end of the bearing region within the socket 1616, such as... Figure 37C As shown. Furthermore, the rotary connector 1602 and the socket 1616 are further configured such that when the truncated ball joint 1606 of the rotary connector 1602 rotates to its maximum extent in any direction within the ball joint engagement region 1628 of the socket 1616, the ball joint opening 1608 is not completely suspended over the ball joint engagement region 1624 within the socket 1616, as... Figure 37E As shown, at least a portion of the spherical joint opening 1608 is substantially aligned with the end of the spherical joint engagement area 1628 within the socket 1616.

[0559] However, in Figures 38A to 38E In the embodiments, the rotary connector 1602 and the socket 1616 are configured such that when the truncated ball joint 1606 of the rotary connector 1602 is in the middle position within the ball joint engagement region 1628 of the socket 1616, the ball joint opening 1608 is completely suspended over the bearing regions 1628, 1630 within the socket 1616, as shown. Figure 38BAs shown. This overhang allows for a shorter overall socket 1616, thus improving compactness. This configuration also allows for a smaller diameter truncated ball joint 1606. Furthermore, the rotary connector 1602 and the socket 1616 are further configured such that when the truncated ball joint 1606 of the rotary connector 1602 rotates to its maximum extent in any direction within the ball joint engagement area 1628 of the socket 1616, the end of the truncated ball joint 1606 is completely overhanging over the ball joint engagement area 1624 within the socket 1616, as shown. Figure 38E As shown.

[0560] Figures 37A to 37E and Figures 38A to 38E Another difference between the embodiments lies in the outer contour of the ball joint engagement region 1624. Figures 37A to 37E In one embodiment, the outer contour of the spherical joint engagement region 1624 facing the surrounding atmosphere has a first slope with respect to the distance from the second end 1626 to point 1650. Figures 37A to 37C ), and has a second slope for the remaining length of the spherical joint engagement region 1624 extending from point 1650 toward the first end 1622, the second slope being different from the first slope. Figures 38A to 38E In one embodiment, the outer contour of the spherical joint engagement region 1624 facing the surrounding atmosphere has a continuous slope, such as... Figure 38B As shown. A continuous inclined surface can be advantageous because it provides a cleaner appearance and requires less complex tooling operations during manufacturing. A continuous inclined surface can also be advantageous because it allows for longer exhaust flow channels ( Figure 38E Expiratory flow 1642 and Figure 37E Compared to the exhalation airflow 1642 in the middle). A longer exhaust flow path can reduce static noise, and especially reduce dynamic noise. The outer contour of the ball joint engagement area 1628, together with the contour of the truncated ball joint 1606, affects the rotational travel of the rotary connector 1602 in the socket 1616. Figure 37C Compared to the outline, Figure 38B The profile allows for shorter rotational travel; this restriction on rotation reduces the chance of crossflow, thus reducing noise.

[0561] Figures 37A to 37E and Figures 38A to 38E Another difference between the embodiments lies in the flow path of inhaled and exhaled gas through the socket 1616. For example... Figure 37EAs shown, the turbulence in the straight portion of the rotary connector 1602 is minimal. However, the intake airflow 1640 expands and separates as it exits the truncated spherical joint 1606, generating turbulence and eddies. When the rotary connector 1602 is in its maximum rotational position, some of the intake airflow 1640 will contact the wall of the socket 1616, which may impede the exhalation airflow 1642. Therefore, some of the exhalation airflow 1642 is restricted, while the exhalation airflow 1642 on the opposite wall of the socket 1616 increases. As described above, Figures 38A to 38E The overhang in the embodiment allows for a smaller diameter truncated ball joint 1606. This configuration can help separate the inspiratory flow 1640 and the expiratory flow 1642, as... Figure 38E As shown. In Figure 38E In this configuration, due to the continuously tapering cylindrical profile of the inner bore of the truncated spherical joint 1606, the intake airflow 1640 does not significantly expand or separate upon exiting the truncated spherical joint 1606. Only slight eddies occur as the intake airflow 1640 exits the truncated spherical joint 1606, caused by the slight tapering of the profile. Furthermore, due to the reduced rotation of the truncated spherical joint 1606 within the socket 1616, even at the position of maximum rotation, most of the intake airflow 1640 does not point towards the wall of the socket 1616. Therefore, apart from slight disturbances from any eddies, the exhalation airflow 1642 is not significantly obstructed by the intake airflow 1640.

[0562] It should be understood that not all differences are limited to the mentioned embodiments. Therefore, they can be addressed through merging. Figures 37A to 37E Modify one or more features of the embodiments Figures 38A to 38E The embodiments are as follows, and vice versa. It should also be understood that the scope of this disclosure does not exclude... Figures 37A to 37E The aforementioned features, even if these features may include those that in some cases can be considered inferior. Figures 38A to 38E The same applies to its advantageous characteristics.

[0563] Figures 40A to 40E Highlighting the Figures 38A to 38E Various exemplary dimensional regions of the embodiments and observations of the present invention. Figure 40A Angles A and F shown (i.e., Figures 37A to 37E and Figures 38A to 38E The arc lengths of the bearing areas 1628 and 1630 can each be within the range of 40° and 80°, wherein the total arc length of the bearing areas (the sum of angles A and F) is within the range of 80° and 160°. In this representation, the angles are the same. However, in other embodiments, the angles may be different. Figure 40A The angles B and H shown (i.e., Figures 37A to 37E and Figures 38A to 38EThe arc lengths of the exhalation regions 1632 and 1634 can each be within the range of 80° and 160°, respectively, wherein the total arc length of the exhalation region (the sum of angles B and H) is within the range of 200° and 280°. Again, in this representation, the angles are the same. However, in other embodiments, the angles may be different. It should be understood that because the sum of angles A, B, F, and H is constant (360°), as the total arc length of the exhalation region increases, the total arc length of the bearing region decreases accordingly.

[0564] refer to Figure 40C Diameter Z (i.e., Figures 37A to 37E and Figures 38A to 38E The inner diameter of the connecting housing 1610 can be in the range of 18 mm to 45 mm. Assuming a wall thickness of 1 mm, the diameter Y is thus in the range of 16 mm to 43 mm. The diameter X is smaller than the diameter Y. According to the following equation, the slot width E ( Figure 40D The value of the slot width E is related to the diameters X and Y: E = ½ (Y – X). The slot width E is preferably in the range of 1 mm to 12 mm. Therefore, in this example, the diameter X is greater than 16 mm.

[0565] refer to Figure 40D When the sphere retention length M increases to the apex of the sphere, leakage decreases. When the sphere retention length M increases beyond the apex of the sphere, leakage decreases and remains improved. It was also found that, according to the following equation, channel depth D1 and channel depth D2 ( Figure 40B The inner diameter (U) of the end of the truncated ball joint 1606 Figure 40D ) and the maximum rotation angle (angle C) of the truncated spherical joint 1606 in any direction within the spherical joint engagement area 1628 of the socket 1616. Figure 40B Related: D1 = D2 + ½(U tan C). Dynamic noise was also observed to improve with increasing channel depth D2. No dynamic noise was observed when channel depth D2 was 7 mm and diameter U was 20 mm.

[0566] The retention area can be defined as the area required to hold the truncated spherical joint 1606 in place. The retention area is a function of angle A, angle G, and the spherical retention length L. For example, refer to... Figure 40EThe angle (angle G) opposite the line representing the ball retention length L decreases as the total arc length of the bearing area (the sum of angles A and F) increases. The exhaust area can be defined as the area required for biased ventilation. The exhaust area is a function of angle B, slot width E, and ball retention length L. Minimizing the retention area maximizes the exhaust area of ​​the expiratory region, thus improving noise and inhalation conditions. Resistance to unwanted shell detachment can be defined as the resistance to accidental shell detachment caused by the torque applied to the shell. Resistance to unwanted shell detachment is a function of diameter Z and shell taper length i. Figure 40D It was found that a maximum ratio of Z to i of 6:1 is preferred.

[0567] V. Respiratory mask and ventilation port arrangement

[0568] Figures 41A to 41E A breathing mask assembly 1700 with an air insertion device is shown, the air insertion device including an integrated bend socket and being compact, easy to manufacture, and easy to clean. The breathing mask assembly 1700 includes a frame 1710, a liner 1712 attached to a cushioning housing 1714, a rotating bend 1716 having a ball joint 1732, and an air insertion device 1718. The air insertion device 1718 is inserted into, received in, and supported by the frame 1710. In operation, the air insertion device 1718 connects the cushioning housing 1714 to the bend 716, such that inhaled gas supplied by a gas supply is supplied through the bend 716 to the liner 1712. The air insertion device 1718 also receives the ball joint 1732 to provide rotatable adjustability of the rotating bend 1716.

[0569] Frame 1710 has a frame opening 1720, which has a generally annular shape defined by an inner wall 1722. Frame opening 1720 has a symmetrical tri-oval shape, the center of which is aligned with the center of frame 1710.

[0570] The vent insert 1718 comprises a cover portion 1740, a mating area 1742, and a bend in the tube recess 1744. The cover portion 1740 has a generally planar shape, the outer surface of which is substantially flush with the outer surface of the frame 1710. The cover portion 1740 and its outer periphery have an annular shape corresponding to the frame opening 1720.

[0571] The engagement region 1742 includes a collar portion 1750 that extends substantially perpendicularly from the periphery of the cover portion 1740 in a direction toward the user. In some configurations, the collar portion 1750 extends from the cover portion 1740 by a distance equal to or greater than the thickness of the frame 1710. The outer surface of the collar portion 1750 has a shape corresponding to the shape of the frame opening 1720, such that the collar portion 1750 engages the inner wall 1722 of the frame opening 1720.

[0572] The cap portion 1740 and the collar portion 1750 define an internal region 1752 of the venting insert 1718. The internal region 1752 provides a cavity within which inhaled and exhaled gases from the rotating bend 1716 and the liner 1712, respectively, are received. The internal region 1752 includes venting areas 1754 disposed on the left and right sides of the engagement region 1742. Ventilation areas 1754 have vents 1756 extending through the cap portion 1740, such that the internal region 1752 is in fluid communication with the atmosphere via the vents 1756. The vents 1756 extend through the cap portion 1740 to deliver the user's exhaled gases into the surrounding atmosphere during use.

[0573] Each ventilation zone 1754 exhausts exhaled air in a different direction than the opposite ventilation zone 1754, so that the exhaled air from the two ventilation zones 1754 does not mix and produce small streams of air or noise that may disturb the user. The ventilation zones 1754 and / or the vents 1756 may be angled so that exhaled air is exhausted in different directions.

[0574] The vent 1756 shown is cylindrical. That is, the vent 1756 has a circular cross-section. In some configurations, the vent 1756 may have a planar shape. A planar shape for the vent 1756 can improve the ease with which the vent 1756 can be cleaned. Those skilled in the art will understand that the vent 1756 is not limited to a circular or planar shape, and can include various shapes and geometries.

[0575] During the assembly of the breathing mask assembly 1700, the ventilation insert 1718 is inserted into the frame opening 1720. In some configurations, the collar portion 1750 and the inner wall 1722 of the frame opening 1720 may have a slight interference fit, allowing the cap portion 1740 of the ventilation insert 1718 to easily engage with the outer surface of the frame 1710 before welding. In other configurations, the collar portion 1750 may have an edge or bevel (not shown) that engages with a corresponding chamfered area on the inner wall 1722, such that the ventilation insert 1718 is correctly positioned relative to the frame 1710.

[0576] The vent insert 1718 is welded to the frame 1710 to provide a permanent connection with the frame. A weld region 1726 of the vent insert 1718 is welded along the joint 1730 between the vent insert 1718 and the frame 1710 to a weld region 1724 of the frame 1710. In some configurations, the vent insert 1718 may engage with the frame opening 1720, for example, by gluing, press-fitting, welding, or brazing. In other configurations, the vent insert 1718 may be removably mounted in the frame opening 1720, for example, by a snap-fit ​​connection. In other configurations, the vent insert 1718 may be integrally molded with the frame 1710 during the molding process.

[0577] The vent insert 1718 has an integrated elbow socket 1744 including a spherical connector bore 1746 and a spherical connector engagement region 1748. The spherical connector bore 1746 extends through the cap portion 1740 of the vent insert 1718. The spherical connector engagement region 1748 includes a bearing surface provided by an upper socket sidewall 1760 and a lower socket sidewall 1762 surrounding the spherical connector bore 1746, as well as a lateral socket sidewall 1764. The inner surfaces of the socket sidewalls 1760, 1762, and 1764 support, retain, provide a sealing engagement, and allow the spherical connector 1732 to rotate relative to the vent insert 1718. In some configurations, the upper socket sidewall 1760 and the lower socket sidewall 1762 may be integrally formed with the inner surface of the collar portion 750.

[0578] The sidewalls of the socket 1760, 1762, and 1764 extend substantially vertically from the periphery of the cover portion 1740. For example... Figure 41D As shown, the central portion 1770 of the lateral socket sidewall 1764 extends further away from the cover portion 1740 than the end portion 1772. That is, the height of the lateral socket sidewall 1764 at the central portion 1770 (i.e., in the direction toward the user) is greater than the height of the lateral socket sidewall 1764 at the end portion 1772. The height of the lateral socket sidewall 1764 gradually decreases from its maximum height at the central portion 1770 to its minimum height at the end portion 1772.

[0579] like Figure 41DAs shown, the end portion 1772 of the lateral socket sidewall 1764 has a similar height to the lower socket sidewall 1762, such that the lower socket sidewall 1762 is flush with the end portion 1772 of the lateral socket sidewall 1764. That is, the user-facing surface of the lower socket sidewall 1762 is flush with the user-facing surface of the end portion 1772 of the lateral socket sidewall 1764. Correspondingly, the height of the central portion 1770 of the lateral socket sidewall 1764 is greater than the height of the lower socket sidewall 1762. In some configurations, the upper socket sidewall 1760 may also have a similar height to the end portion 1772 of the lateral socket sidewall 1764.

[0580] The shorter height of the end portions 1772 of the lower socket sidewall 1762 and the lateral socket sidewall 1764 forms a recessed region 1780. That is, the user-facing surfaces of the lower socket sidewall 1762 and the lateral socket sidewall 1764 define the recessed region 1780 between the ball joint 1732 and the collar portion 1750. The recessed region 1780 provides a shallow, user-accessible cavity in areas within the internal region 1752 where dirt may accumulate. The recessed region 1780 provides a shallow gap or void between the ball joint 1732 and the bottom of the vent insert 1718 (i.e., the collar portion 1750), which can be easily wiped and cleaned by the user.

[0581] In some configurations, a portion of the inner surface of the collar portion 1750 adjacent to the lower socket sidewall 1762 may have a cut-off area, which further enlarges the recessed area 1780. That is, a portion of the collar portion 1750 adjacent to the recessed area 1780 can be removed or recessed to enlarge the recessed area 1780. The inner surface of the collar portion 1750 may be recessed, reducing the thickness of the collar portion 1750 while providing additional clearance between the collar portion 1750 and the ball joint 1732.

[0582] In some configurations, the upper socket sidewall 1760 may also have a similar height to the end portion 1772 of the lateral socket sidewall 1764, creating a recessed area above the ball joint 1732 that facilitates cleaning in the upper region of the vent insert 1718. Similarly, a portion of the inner surface of the collar portion 1750 adjacent to the upper socket sidewall 1760 may have a cut-off area that further enlarges the recessed area.

[0583] In some configurations, the ball joint 1732 may have a cut-off area (not shown) on the bottom portion of the ball joint that engages with the inner region 1752. The cut-off area may be a removed or recessed portion of the ball joint 1732, which is aligned with the recessed region 1780 and provides additional clearance between the collar portion 1750 and the ball joint 1732 to allow a user to remove dirt build-up within the inner region 1752 of the vent insert 1718.

[0584] Figure 42A and Figure 42B An alternative breathing mask assembly 1800 is demonstrated for bias ventilation in a full-face mask having an ventilation insert 1818 including an integrated elbow socket. The configuration of the ventilation insert is substantially similar to... Figures 41A to 41E The breathing mask assembly 1700 features a side-ventilation configuration. However, the bias vent 1854 is located above the rotating bend 1816 rather than on the side. Therefore, the mask assembly 1800 is compact, easy to manufacture, and easy to clean. For simplicity, Figures 41A to 41E The breathing mask assembly 1700 in the middle and Figures 42A to 42B Redundant discussion of similar features between alternative breathing mask components 1800 is omitted.

[0585] The bias vent 1854 has a plurality of vent holes 1856 disposed in the vent insert 1818. The vent holes 1856 extend through the vent insert 1818 to deliver the user's exhaled air to the surrounding atmosphere during use.

[0586] A vent insert 1818 may extend through an aperture in the frame 1810 and provide a connection between the frame 1810 and the cushioning housing 1814. The vent insert 1818 is permanently attached to the cushioning housing 1814 of the face mask. The vent insert 1818 may be friction-fitted / press-fitted or welded to provide a permanent engagement with the frame 1810. In other configurations, the vent insert 1818 may be removably attached to the frame 1810, for example, by a snap-fit ​​or latching connection. In other configurations, the vent insert 1818 may be integrally molded with the frame 1810 during the molding process.

[0587] The vent insert 1818 also includes a bend socket 1844 for receiving a spherical connector 1832 that receives a rotating bend 1816. Similar to... Figures 41A to 41E The elbow socket 1744 and elbow socket 1844 support, retain, and provide a sealing engagement, and allow the ball joint 1832 to rotate relative to the vent insert 1818. The elbow socket 1844 includes a similar socket sidewall configuration and recessed area to allow easy cleaning of the vent insert 1818.

[0588] Headgear

[0589] Respiratory patient interfaces / masks can be used to treat a variety of conditions. One such condition is obstructive sleep apnea (OSA). Certain features, aspects, and advantages of the invention described herein are described with reference to its use in the treatment of OSA via continuous positive airway pressure (CPAP); however, this is not intended to be limiting, and certain features, aspects, and advantages of the invention can be used to treat other respiratory conditions.

[0590] The most common treatment for OSA is CPAP. This involves a continuous supply of pressurized air to the patient's airway via a mask system. Most masks consist of a combination of a sealing interface, frame, air supply connector, and headgear structure. The headgear is attached to the frame and holds against the patient's face to maintain a seal. For therapeutic efficacy, a substantially leak-free seal between the mask and the patient's face is required. Therefore, the headgear structure is integrated when securing the mask to the patient.

[0591] Headgear is typically made of breathable foam and fabric laminates such as Breath-o-Prene®. Some common problems associated with current headgear designs include their bulkiness, weight, heat, and slow drying time when cleaned. Certain features, aspects, and advantages of the present invention attempt to provide improvements to these problems.

[0592] 3D fabric

[0593] Some features, aspects, and advantages of the present invention include headgear constructed wholly or partially from 3D fabrics. 2D fabrics are typically woven from two groups of yarns as warp and weft to form a woven surface or sheet material. The thickness of a 2D fabric is determined by the combined thickness of the yarns at the yarn intersections in the fabric. For example, in a fabric woven from warp and weft, the thickness of the fabric is equal to the thickness of the warp and weft yarns used in the construction of the fabric. Yarns in 2D fabrics typically extend in a single plane of the fabric. 2D fabrics lack fibers or yarns extending in the full thickness direction of the fabric and primarily have yarns extending only in the generally planar direction of the fabric. Two-dimensional textiles or fabrics (such as woven and knitted sheet fabrics) tend to form sharp edges when pleats in 2D fabrics are flattened or tension is applied along the folds. For example, sharp folds form when pleats in 2D fabrics are placed under heat and / or pressure (e.g., ironing). Folded edges in 2D fabrics are generally undesirable in headgear applications because the tension in the headgear components required to maintain a sealed position on the user's face can create sharp edges. This is especially undesirable when applied to soft tissue or sensitive areas of the user's head, such as around the ears or behind the neck.

[0594] All fabrics have a 3D internal structure; however, macroscopically, most can be considered thin 2D fabrics. In 3D fabric structures, the thickness, or Z-axis dimension, is considerably larger than the X and Y dimensions. 3D fabrics can generally be defined as “a single fabric system in which the constituent yarns are arranged in three mutually perpendicular planes” (Behera BK, Mishra R. (2008), 3-Dimensional Weaving, Indian Journal of Fiber and Textile Research, Vol. 33, pp. 274-287). Indian Journal of Fiber & Textile Research Khokar provides a similar definition for 3D fabrics: “A fabric in which the constituent yarns are arranged in a relationship of three mutually perpendicular planes” (Khokar, N. (2001), 3D-Weaving: Theory and Practice, Journal of the Textile Institute, Vol.92 No.2, pp.193-207).

[0595] A basic and common definition of 3D fabrics is that these types of fabrics have a third dimension within a thickness layer. For example, 3D fabrics have yarns in the warp, weft, and full thickness directions. Khokar categorizes 3D fabrics into different types, including interwoven 3D fabrics, non-interwoven 3D fabrics, and fully interwoven 3D fabrics.

[0596] In this specification and claims, unless the context otherwise requires, the term "yarn" is intended to mean a yarn, filament, fiber, thread, or any other constituent element used to form a fabric by means of weaving, knitting, braiding, or other construction.

[0597] As mentioned above, the thickness of 3D fabrics is greater than the stacking of the constituent yarns used in the fabric's construction. In other words, compared to conventional 2D textiles, 3D fabrics have a relatively lower density in terms of the thickness of their constituent materials compared to the overall fabric thickness. The construction of 3D fabrics provides a thicker fabric that is lightweight and breathable for a given fabric thickness because it is less dense than conventional 2D fabrics for that thickness. Furthermore, the structure of 3D fabrics is less prone to wrinkling when folded, and the increased thickness compared to 2D fabrics provides additional cushioning.

[0598] One form of 3D fabric is a 3D spacer fabric or textile (referred to as 'spacer fabric' in this document), which is a fabric consisting of two sheets connected by a series of yarns (e.g., filaments or fibers) extending between the sheets, such as... Figure 43 As shown. Reference Figure 43 The spacer fabric may include a first sheet 2101 formed in a first plane by one or more yarns (e.g., warp and weft yarns), a second sheet 2102 formed in a second plane parallel to the first plane by one or more yarns (e.g., warp and weft yarns), and one or more yarns 2103 extending in the full thickness direction of the fabric and connecting the two sheets together. The distance between the sheets and the physical properties of the fabric sheets and the filaments extending or connecting the sheets can be specified to provide various physical properties. In some embodiments, the distance between the sheets may fall within the range of 1 mm to 5 mm.

[0599] Spacer fabrics are typically breathable, provide compressible cushioning, are lightweight, hypoallergenic and antibacterial, and can be stretched or unstretched. Spacer fabrics are usually made from thermoplastics such as polyester, but can also be made from a variety of other fibrous materials. Different combinations of materials can be used to provide specific physical properties.

[0600] By way of example only, embodiments disclosed herein include 3D spacer fabrics. Other types of 3D fabrics may be used as alternatives to or in combination with the described 3D spacer fabrics in the disclosed embodiments.

[0601] Figure 44 illustrates a typical headgear design for a full-face mask. The typical headgear design includes four mask attachment points, which take the form of adjustable upper and lower side straps, an adjustable top strap, and a back section. Figure 45 The same headgear is shown in its flat position. A similar four-point headgear configuration can be used in conjunction with a nose mask. For some direct nose masks, a two-point headgear configuration is used. These configurations tend to have attachment straps positioned more centrally on each side of the headgear. Furthermore, the four-point headgear can be attached to a face mask with or without a T-shaped piece.

[0602] In some configurations, the headgear can be broadly shaped as follows: Figure 45As shown, but may also be made at least partially of spacer fabric. For example, the back section or back panel portion 2301 may be made of spacer fabric, and the rest of the headgear may be made of conventional materials, such as breathable foam and fabric laminates. The back panel of the headgear provides a section of the headgear from which headgear straps extend in desired positions and orientations to fit the heads of many different users. The back panel is typically larger and bulkier than other parts of the headgear, such as the headgear straps.

[0603] The back panel is large enough to provide stability to the headgear on the user's head. The panel contacts a sufficient area of ​​the user's head to help maintain proper placement of the headgear. However, because the panel covers a large area of ​​the user's head, the headgear may be hot and uncomfortable for the user. Using spacer fabric in the back portion 2301 of the headgear can help reduce the overall weight of the headgear and improve its breathability, thereby improving user comfort and reducing sweating and / or lowering the temperature that the user's scalp covered by the headgear may reach. Spacer fabric can be more compressible than conventional headgear materials such as breathable foam and fabric laminates. This is advantageous because it makes the headgear less noticeable on the patient's head when the patient is lying down. The thickness of conventional materials can mean that the patient can feel the headgear between their head and the pillow, and / or the edges of the headgear can be embedded in the head. Because spacer fabric can be compressed to a minimum thickness, it is less likely to be felt on the patient's head.

[0604] The use of spacer fabric as a component of a headgear is not limited to this location. Any component of the headgear can be made of spacer fabric, where the physical properties of the fabric are selected to meet the requirements of a specific location. Alternatively, the entire headgear can be made entirely of one or more grades of spacer fabric. Combinations of spacer fabrics with different physical properties can be incorporated into a single headgear. For example, the straps attached to the face mask can be non-stretchable, and the back panel can be made of a thicker material to provide additional cushioning.

[0605] Several physical properties of headgear fabrics are advantageous. These physical properties include a soft, smooth surface for contact with the patient, being stretchable or non-stretchable depending on its position within the headgear, and having a certain amount of rigidity to maintain the shape of the headgear.

[0606] Spacer fabrics are typically manufactured in large sheets, from which headgear components are cut and assembled. The cut edges of the fabric are preferably finished in a certain way to reduce the possibility of abrasion, an unsightly appearance, and rough edges against the patient's skin. Many techniques and methods can be used to assemble headgear components and finish the edges. Several embodiments of these techniques and methods are detailed below.

[0607] Edge finishing technology

[0608] Figure 46A , Figure 46B , Figure 46C and Figure 46D This demonstrates several edge finishing methods that can utilize welding and / or stitching techniques. For example... Figure 46A As shown, welding and die-cutting can be used to create sealed and neat edges. Heat generated by welding techniques such as radio frequency (RF) welding can be used to melt the fabric that joins the outer fabric sheets of the spacer fabric together, creating closed edges and sealing the filament areas between the sheets. Once the edges are sealed, they can be trimmed and finished using die-cutting methods. In some configurations, individual headgear components can be joined together using RF welding to form a complete headgear. This allows combinations of different grades or types of fabrics to be used within a single headgear; for example, multiple grades of spacer fabric can be joined together, or spacer fabric components can be joined to breathable foam and fabric laminate components.

[0609] Figure 46B and Figure 46C An embodiment of edge finishing is shown, wherein the outer surface of the spacer fabric extends further than the inner filaments and folds over the exposed edges of the spacer fabric. Figure 46B In the middle, both the upper and lower surfaces extend and then fold towards the center of the fabric. The folded edges are secured in place by welded joints passing through the outer surface of the spacer fabric. As an alternative to or supplement to welding, a series of stitches can be sewn into the edge of the spacer fabric, which lock the folded opening. Figure 46C In this process, one outer surface extends further than the other and is folded over the entire edge of the spacer fabric. The folded vent is then welded and / or sewn in place as in the previous embodiment.

[0610] Figure 46D Another embodiment utilizing welding technology is illustrated. A separate finishing element can be applied to the edge of the spacer fabric, wherein the finishing element can be made of textile or plastic. Textiles such as bias-cut fabric can be folded over the edge of the spacer fabric and secured in place by sewing through the outer sheet of the fabric and the inner spacer element, or by welding the outer sheet of the fabric and the inner spacer element together. In some configurations, molded plastic beaded edges or shells can be applied to the edge of the spacer fabric using welding and / or sewing techniques or any other suitable method. For example, but not limited to, the molded beaded edges or shells can have a circular or rounded cross-section.

[0611] Overmolding is another technique that can be used to provide finished edges on spacer fabrics. Figure 46E This illustrates a cross-section of a beaded edge that can be molded onto the edge of a spacer fabric headgear. The cross-section of the beaded edge can be as follows: Figure 46E The shape shown is essentially trapezoidal, or any other suitable cross-sectional shape. The overmolded bead edge can be made of a soft material such as a thermoplastic elastomer to provide comfortable contact between the headgear and the patient. This finishing technique can also provide a source of structural reinforcement for the headgear, thus providing non-stretchable or semi-rigid portions within the headgear. The overmolded material can be overmolded onto the outer surface of the spacer fabric edge using any suitable molding technique. The overmolded material can be overmolded into the spacer fabric in a three-dimensional shape so that the headgear retains its structure when not on the patient's head. This helps reduce the likelihood of headgear strap tangling and also makes the headgear easier to fit. Due to the open structure of the spacer fabric, overmolding can result in plastic material being placed on the outer surface of the spacer fabric and / or through the spacer fabric layers. Figure 46E This shows the overmolded edge material molded onto the outer surface of the fabric. Figure 46F This illustrates a possible configuration in which the plastic edge material has permeated all layers of the spacer fabric.

[0612] Figure 46G Another embodiment shown utilizes a heat-sealing knife technique to seal and trim the spacer fabric. The headgear components can be die-cut from a larger sheet of spacer fabric using a heat-sealing knife. Before cutting through the fabric, the heat-sealing knife compresses and melts the two outer sheets and filament areas together. This method leaves neat edges on the spacer fabric because the shape of the sealed edge perfectly matches the shape of the cut piece.

[0613] Stitching techniques such as overlocking (binding) and using bias cuts can be used to make the edges neat.

[0614] Figures 47A to 57 Several embodiments of headbands incorporating spacer fabric are illustrated in these figures. Each headband in these figures includes a back panel 2301 from which straps extend, as previously described. As shown, the headband may include a lower strap 2156, an upper strap 2152, and a top strap 2154. In the illustrated embodiments, the headband includes lower left and lower right straps, upper left and upper right straps, and upper left and upper right straps. The left and right straps (e.g., lower left and lower right straps) are joined together in use. However, in some embodiments, one or more of the lower, upper, and top straps may be configured as a single strap attached to each side of the back panel of the headband. The left and right straps (e.g., top strap 2154) may be joined using buckles or clamps or other components, and / or may include features that allow the straps to be joined together, such as those described in U.S. Application 62 / 187010, the contents of which are incorporated herein by reference.

[0615] In some embodiments, at least a portion of the rear panel 2301 includes a spacer fabric. In some embodiments, at least a portion of the rear panel includes two layers of spacer fabric. For example, as... Figure 47A and Figure 47B As shown, in some embodiments, the rear panel 2301 includes: a spacer fabric pad or panel 2201 comprising two layers of spacer fabric; and a lower rear stripe 2158. The spacer fabric panel 2201 includes a generally rectangular portion having a fan-shaped edge with its corners cut off. The cut-off corners are configured to attach to the upper stripe 2152 and the lower stripe 2156. The spacer fabric sheet 2201 includes two spacer fabric layers 2232 stacked on top of each other. The spacer fabric layers have a front side 2233 and a back side 2234. The two layers can be sewn together with the inside facing out (i.e., with the back of the fabric facing outwards) to form a seam 2236 near the vent 2238 of the spacer fabric layer. Once sewn together, the layers 2232 are then turned outwards so that the front side 2233 is on the outside and the vent 2238 is on the inside. The seam 2236 extends around the periphery of the spacer fabric pad 2201, keeping the bottom edge 2239 open. The open bottom edge 2239 allows the right side of the spacer fabric pad 2201 to be turned outwards. Once the right side is turned outwards, the upper stripe 2152 and the lower rear stripe 2158 are attached to the spacer fabric pad 2201. The lower and upper stripes can be sewn onto the spacer fabric; however, other attachment methods, such as, but not limited to, welding or bonding, may also be suitable. Figure 47A In the illustrated embodiment, the strip and fabric are welded to form a weld joint 2210 between the strip and the two layers of spacer fabric. The open bottom edge 2239 can be sealed (closed) while being attached to the lower rear strip 2158. The lower rear strip can be integrally formed with the lower strip.

[0616] The lower rear strap 2158 extends along the bottom edge 2239 of the spacer fabric pad. The lower rear strap 2158 may be made of a material less elastic than the spacer fabric pad 2201. The lower rear strap provides structural reinforcement to the spacer fabric pad 2201 to reduce or eliminate the possibility of overstretching, which could cause the mask to shift off the user's face during use.

[0617] Figure 48 One embodiment is shown in which the bottom edge of the spacer fabric panel is positioned above or across the user's neck during use. Two layers of spacer fabric can be sewn together, with the right sides of the fabric facing inwards and then turned outwards so that the fabric vents are on the inside of the back panel, as described above. However, in cases such as Figure 48In some embodiments shown, a layer of the spacer fabric may include an opening such as a hole or slit (shown by dashed line 2203) that allows the layer to be turned face-out. In this way, all four edges of the back panel can have fabric vents that turn inside out into the back panel. In such embodiments, opening 2203 may be covered by a patch 2205, which is, for example, a label bearing the manufacturer's logo or brand. Alternatively, in some embodiments, the two layers of fabric may be turned face-out via one of the cut-out corners of the back panel.

[0618] In some embodiments, the back panel may include two layers of spacer fabric panels and a peripheral portion extending around the spacer fabric, the peripheral portion being formed of another material suitable for headwear, such as typical headwear materials, like breathable foam and fabric laminates. Figure 49 In some embodiments, the back panel 2301 includes two layers of spacer fabric 2201 and a peripheral portion 2160 formed of another headband material extending around the entire periphery of the spacer fabric. In some embodiments, the back panel may include two layers of spacer fabric and a peripheral portion formed of another headband material extending around a portion of the periphery of the spacer fabric. This other headband material, such as a breathable foam and fabric laminate, may extend into and / or form headband straps, such as a lower strap 2156 and an upper strap 2152. In some embodiments, the lower strap and / or headband strap may be integrally formed via the peripheral portion of the back panel, wherein the peripheral portion and the strap are formed of the same material. The two layers of spacer fabric panel 2201 may be attached to the material of the peripheral portion 2160 by adhesive, sewing, welding, or other joining methods. In such embodiments, the edges of the spacer fabric layers may be sealed / closed and attached to the material of the peripheral portion by joining methods (e.g., welding). The peripheral portion extending along the bottom edge of the rear panel can be described as a rear strip, for example, as... Figure 47A The rear strip is 2158.

[0619] exist Figure 49 In embodiments such as Figure 47A and Figure 48Compared to other embodiments, such as this one, the rear strap 2158 or its peripheral portion extending along the bottom edge of the rear panel has a 'greater rise' or includes a pronounced inverted (upside down) V-shape. This greater rise or pronounced V-shape is provided by shortening the radius of curvature in the bottom edge of the rear panel and / or reducing the angle at which the lower strap extends from the rear panel between the lower straps. In some embodiments, the lower strap 2156 is at an angle of approximately 45 to 70 degrees, measured from the vertical centerline of the headband. If the angle of the lower strap when laid flat is less than 45 degrees (i.e., the strap is 'overly horizontal' oriented in use), then the lower strap 2156 may come into contact with the user's ear during use. If the angle of the lower strap 2156 is greater than 70 degrees (i.e., the strap is 'overly vertical' oriented in use), then the strap can twist and embed itself into the user as the lower strap 2156 is aligned to extend forward and upward from a never-twisted position to attach to the patient interface.

[0620] In some embodiments, the back panel, or a portion of the back panel including two layers of spacer fabric, is formed by folding a sheet or blank of spacer fabric. The sheet or blank of spacer fabric is folded to provide two layers of spacer fabric to form at least a portion of the back panel 2301. The spacer fabric may have a front and a back side, and is folded such that the back side of the fabric is on the inside of the panel, while the front side of the fabric is on the outside of the panel. Folding the spacer fabric provides a folded edge for the spacer fabric in the back panel. For example, refer to… Figure 50 In some embodiments, a folded edge 2220 is provided at the bottom edge of the back panel. The bottom edge of the back panel is located above or on the user's neck. In some applications, the bottom edge of the headgear extending across the user's neck is preferably soft. Placing the folded edge at the bottom edge of the back panel provides a soft edge in this location, which can improve user comfort. Because the folded edge does not include any joining structures such as stitches, welds, or adhesives, it is particularly soft and can also provide additional flexibility, which may be preferred in some applications. In some embodiments, the other edges of the two layers are joined together by adhesives, stitches, or welds. For example, in Figure 50 In one embodiment, all edges of the two layers, except for the folded edge, are welded together. Figure 50 In some embodiments, the back panel has a peripheral portion extending from one end of a folded edge to the other end of the folded edge around two layers of spacer fabric. The peripheral portion of the back panel is formed of a material suitable for headwear, such as foam or other fabric materials (e.g., breathable foam and fabric laminates) or a single layer of spacer fabric. In some embodiments, the edges of the two layers of spacer fabric, excluding the folded edge, are attached to the peripheral portion by adhesive, sewing, welding, or other joining methods. Figure 50In some embodiments, the edges of the two layers of spacer fabric, excluding the folded edges, are welded to a peripheral portion of the back panel. In some embodiments, the material of the peripheral portion may extend into and form at least a portion of the headband straps (such as lower and / or upper straps).

[0621] In some embodiments, the edges of the two spacer fabrics, excluding the folded edges, may be joined together using one or more joining methods to achieve desired properties. For example, in some embodiments, one or more edges may be sewn together, and one or more edges may be welded or glued together. In some embodiments, the two spacer fabrics are welded or glued together along each lateral edge of the two spacer fabrics. In some embodiments, the two spacer fabrics are sewn together along the edges of the two spacer fabrics opposite to the folded edges of the two spacer fabrics. For example, as... Figure 51 As shown, in some embodiments, the two layers of spacer fabric are welded together along each lateral edge 2221 of the two layers of spacer fabric and sewn together along the edge 2222 of the two layers of spacer fabric opposite to the hem 2220. In such embodiments, the bottom hem 2220 provides a particularly soft edge. For example, the upper sewn edge can also be particularly soft if soft yarn or thread or elastic yarn or thread is used for sewing. In an alternative configuration, the spacer fabric may include a hem at one edge 2220 of the back panel and a second hem at the opposite edge 2222 of the back panel, wherein a joint is present in one of the two layers of spacer fabric. For example, the spacer fabric of the back panel may be at the upper edge of the back panel ( Figure 51 It has a folded edge 2222 at the edge 2222 in the middle, and at the bottom edge of the back panel ( Figure 51 The outer layer of the two-layer spacer fabric may have a folded edge 2220 at its edge 2220. The outer layer is positioned away from the user's head during use. Figure 56 An exemplary cross-section is provided. In some embodiments, the joint may be covered by a patch, which is, for example, a label bearing a manufacturer's logo or brand. The joint 2210 may be a welded joint. Non-welded material may be disposed between the two layers of spacer fabric (in... Figure 56 (Not shown in the image), so that when the joint 2210 is welded, the two layers will not weld together. The non-welding material can be, for example, a material that is not weldable at the welding temperatures of the spacer fabric and the underlying material. A non-adhesive or non-welding film or material prevents the layers of the spacer fabric from joining together. In another alternative embodiment, the 3D fabric can be formed as a continuous tube, for example, a knitted tube. To achieve two layers of 3D fabric, the tube of the 3D fabric is flattened to provide two layers of 3D fabric with folds at each of the two opposite edges. The cross-section of the two layers of 3D fabric can be as follows: Figure 56As shown, however, since the two layers are formed by flattened tubes, there is no joint 2210.

[0622] Due to the adhesive or welded joints, or due to changes in fabric structure caused by the adhesive material, the welded or bonded joints have higher stiffness than the spacer fabric. Welded or bonded joints have less tensile strength than folded edges. For example, as... Figure 51 The illustrated embodiment can provide a back panel with higher horizontal tension in the lateral direction (from side to side) compared to the longitudinal direction (the user's direction from top to bottom). The generally vertical welded edges of the two layers of spacer fabric are less flexible than the sewn and / or folded lateral edges. Figure 51 In one embodiment, the rear panel 2301 comprises a panel consisting of two layers of spacer fabric 2201 and a peripheral portion 2160 at each lateral edge, the peripheral portion being formed of another material suitable for a headgear, such as typical headgear materials, such as breathable foam and fabric laminates. In the illustrated embodiment, the lateral edges 2221 of the two layers of spacer fabric are welded to the corresponding lateral peripheral portions 2160. Each peripheral portion 2160 may extend into and form at least a portion of a headgear strap (such as a lower strap 2156 and / or an upper strap 2152). Welding the spacer fabric to the peripheral portions may also bring the edges of the two layers of spacer fabric together or join them.

[0623] exist Figure 50 and Figure 51 In some embodiments, when the spacer fabric is folded along a straight fold line, the folded edges 2220 of the two layers of spacer fabric are straight edges. In some embodiments, such as Figure 52 As shown, the fold 2220 can be curved, for example, by wrinkling each layer of spacer fabric near the fold, for example, by pleating the layers on the fold line 2225.

[0624] In such Figure 53 In some embodiments shown, the fold 2220 may be located at the lateral edge 2221 of the rear panel 301. The two layers of spacer fabric may be sewn together along the lateral edge 2222 of the two layers of spacer fabric opposite to the fold 2220. Alternatively, the spacer fabric may include two folds, for example, as shown in the reference. Figure 51 However, the folded edge is located at the lateral edge of the two layers of spacer fabric. The upper and lower edges of the two layers of spacer fabric can be glued, welded, or sewn to the upper and lower straps of the headgear. Figure 53 In one embodiment, two layers of spacer fabric are welded 2210 to the upper strip 2159 and the lower strip 2158 along the upper and lower edges, respectively.

[0625] In some embodiments, the spacer fabric can be applied to the headwear by wrapping it around another component of the headwear. For example, as... Figure 54 and Figure 49 As shown, the headgear may include a back panel formed of headgear materials such as breathable foam and fabric laminates, or other suitable materials covered with spacer fabric. Figure 54 and Figure 55 In some embodiments, the spacer fabric is wrapped around another headgear material of the back panel. In some embodiments, the two layers of spacer fabric may be joined at the edges, for example, by sewing, gluing, or welding. Figure 54 and Figure 55 As shown, in some embodiments, the spacer fabric is wrapped around another headgear material to have pleats 2220 at the upper and lower edges of the back panel. One of the two layers of spacer fabric may have a joint, for example, made of... Figure 54 The dashed line 2224 indicates a joint that is sewn, glued, or welded. This joint may be located between two layers of spacer fabric, the outer layer being a layer that does not contact the user's head during use. Figure 55In the cross-sectional view, the shown joint 2224 is a welded joint 2210. In some embodiments, the joint 2224 in the spacer fabric may be formed before the spacer fabric is wrapped around another headgear material. In such embodiments, the fabric is joined to form a continuous piece of fabric with open ends for fitting over another headgear material. Alternatively, in some embodiments, the fabric may be wrapped around another headgear material and then joined. In some embodiments, the joint in the spacer fabric layer may also join the spacer fabric to the underlayer material of the headgear. In some embodiments, a non-adhesive or non-welding material or film may be provided between the underlayer material of the headgear and one or two layers of spacer fabric. The non-adhesive or non-welding material may be a material incompatible with adhesive materials, such that no adhesive is formed with the non-adhesive material. The non-welding material may be, for example, a material that is not weldable at the welding temperatures of the spacer fabric and the underlayer material. The non-adhesive or non-welding film or material prevents one or more layers of spacer fabric from attaching to the underlayer material of the headgear. For example, a non-welded membrane 2240 may be disposed between the base material 2245 of the headgear and the spacer material layer 2237 (the inner layer of the two spacer fabrics) that contacts the user's head during use. The non-welded material or membrane 2240 prevents weld joints 2210 in the outer layer 2235 of the spacer fabric from penetrating the base material 2245 and the inner layer 2237 of the spacer fabric, thus preventing the inner layer of the spacer fabric from being welded to the base material. However, welds in the outer layer 2235 of the spacer fabric can weld the outer layer of the spacer fabric to the base material 2245. Adheding or welding the outer layer of the spacer fabric to the base material helps maintain the spacer fabric covering in the correct position on the base material. The inner layer 2237 of the spacer fabric separates the base material of the headgear from the user's head, which can improve comfort by providing a cushioning effect and also reduce sweating and / or lower the temperature that the user's scalp covered by the headgear may reach.

[0626] Figures 47A to 54 One embodiment of the headgear includes two layers of spacer fabric in at least a portion of the back panel of the headgear. However, in some embodiments, the two layers of spacer fabric may be used in other parts of the headgear or for forming other parts of the headgear. For example, as... Figure 57 As shown, in some embodiments, the headband strap 2156 may include two layers of spacer fabric 2232. The spacer fabric 2232 may be formed with a pleat 2220 at one edge of the strap and a joint at the opposite edge 2222 of the strap, or with a pleat 2220 at one edge of the strap and a pleat at the opposite edge 2222 of the strap, with the joint in one of the two layers of spacer fabric 2232. For example, the joint may be located in the outer layer of the spacer fabric, as per [reference to...]. Figure 54 As explained in the embodiments.

[0627] Refer to the above Figures 51 to 57 In the manufacture of the described embodiments, in some embodiments, the joint between the layers of two spacer fabrics or within one layer can be manufactured with the reverse side of the fabric turned outwards. Once the joint has been made, the right side of the spacer fabric is then turned outwards, such that the joint is located inside the two layers of spacer fabrics, for example, as referenced. Figure 47A As described in the embodiments.

[0628] Welding details

[0629] In some embodiments, such as reference Figure 50 The aforementioned method involves welding one or more edges of the two-layer spacer fabric panel to another part of the headgear, such as the periphery of the back panel. For example, in... Figure 50 In this configuration, the edges of the two layers of spacer fabric are welded to a peripheral portion 2160 of the back panel, the peripheral portion extending from one end of a fold 2220 to the other end of the fold. And... Figure 51 In this embodiment, the lateral edges 2221 of the two layers of spacer fabric 2201 are welded to the lateral peripheral portion 2160. In some embodiments, the portion of the headgear is formed of another material suitable for the headgear, such as a breathable foam and fabric laminate.

[0630] In some embodiments, the edge regions of the two spacer fabric layers overlap with the edge regions of said portion of the headgear to form a weld region comprising the two spacer fabric layers and said portion of the headgear. In the weld region, one layer of the spacer fabric (inner layer) lies between said portion of the headgear and another layer of the spacer fabric (outer layer). The overlapping materials constituting the two spacer fabric layers and said portion of the headgear are preferably welded together by radio frequency welding, wherein, as is known in the art, the materials are pressed together between two welding heads (e.g., between a worktable / plate and a mold / welding head). However, any other suitable welding technique may be used, such as ultrasonic welding or thermocompression welding.

[0631] In some embodiments, such as Figure 59BAs shown, in weld region 2250, one layer 2235 (overlapping layer) of the two spacer fabrics overlaps the edge of the other layer 2237 of the two spacer fabrics, such that the weld includes a first region 2250A formed by the two spacer fabrics and a portion 2160 of the headgear, and a second region 2250B formed by a single layer of spacer fabric and the same portion of the headgear. In some embodiments, the weld includes a first region 2250A formed by the two spacer fabrics and a portion 2160 of the headgear, and a second remaining region 2250B formed by a single layer of spacer fabric and the same portion of the headgear. This arrangement forms a weld with a 'stepped thickness' of the welded spacer fabric. The thickness of the welded spacer fabric is greater at the edge 2160A of the headgear than at the edge 2235A of the overlapping layer 2235 of the spacer fabric.

[0632] Each of the two spacer fabric layers has an overlapping area that overlaps with a portion of a headgear to be welded to the two spacer fabric layers. The width of the overlapping area of ​​the first layer is greater than the width of the overlapping area of ​​the second layer of the two spacer fabric layers. For example, see reference... Figures 58A to 5 9C, two layers of spacer fabric can be formed by folding a single blank 2300 cut from a spacer fabric sheet. For example... Figure 58B and Figure 58C As shown, the preform is folded to form two layers of spacer fabric. The fabric runs along... Figure 58A The folding region 2310 shown is folded. A segment 2315 of the preform forming one layer 2237 of the two-layer spacer fabric is determined to be smaller than the corresponding segment 2320 of the preform forming the second layer 2235 of the two-layer spacer fabric, such that once the fabric is folded along the folding region 2310 to form the two-layer spacer fabric, one layer 2235 overlaps the edge of the other layer 2237, as shown. Figure 58B and Figure 58C As shown. When the edges of one layer 2235 overlap with those of another layer 2237, the two spacer fabrics include 'stepped edges'. In the illustrated embodiment, the two spacer fabrics have stepped edges at each lateral edge 2221 of the two spacer fabrics. At edge 2222, opposite to the hem 2220, the edges of the layers are aligned to, for example, provide a seam edge. Therefore, Figure 58B The two-layer spacer fabric shown can be applied to Figure 51 The structure of the headgear shown. (As shown) Figure 58B As shown, folds in the spacer fabric result in rounded edges. Unlike folds in 2D fabrics that can lead to sharp, wrinkled edges, folds in 3D fabrics produce soft, rounded edges. Due to the thickness and / or structure of the 3D fabric, the fold 2220 creates a gap between the two layers of fabric at the fold, making the edge particularly soft and suitable for headwear.

[0633] Figure 58D An alternative preform for forming two layers of spacer fabric is shown. In this embodiment, the preform includes two folded regions 2310A and 2310B. Once folded over the two folded regions to form two layers of spacer fabric, one of the two layers includes a joint formed in the joining region 2325 of the preform. A segment (or segments) of the preform forming one layer of the two layers of spacer fabric is determined to be slightly smaller than the corresponding segment (or segments) of the preform forming the second layer of the two layers of spacer fabric, such that once the fabric is folded along folded regions 2310A and 2310B to form two layers, one layer 2235 overlaps with the edge of the other layer 2237. In the illustrated embodiment, the segment of the preform forming the overlapping layer includes two segments 2320A and 2320B, which together form the overlapping layer of the two layers of spacer fabric, such that the joint formed in the joining region 2325 of the preform (e.g., Figure 56 The joint 2210 is formed in the overlapping layer 2235 of the spacer fabric. Figure 58D The raw material is formed into a two-layer spaced fabric with two folds, such as Figure 56 As shown.

[0634] As previously described, in some embodiments, the 3D fabric can be formed as a continuous tube, such as a knitted tube. To achieve two layers of 3D fabric, the tube of the 3D fabric is flattened to provide two layers of 3D fabric with folds at each of two opposing edges. In such embodiments, a 'stepped edge' can be achieved by cutting or otherwise forming a tube having a first tube length extending the first half of the tube circumference and a second tube length extending the other half of the tube circumference, wherein the first length and the second length are different to form a stepped edge when the tube is flattened so that the first and second halves of the tube circumference come together.

[0635] In some embodiments, in the weld area, the outer layer of the spacer fabric overlaps with the edge of the inner layer of the spacer fabric. For example, Figure 59A The material stack is shown prior to welding. The stack shows the portion of the headgear 2160 overlapping with the inner layer 2237 and outer layer 2235 of the spacer fabric. The outer layer 2235 of the spacer fabric overlaps with the edge 2237A of the inner layer 2237. In an alternative embodiment, the inner layer may overlap with the edge of the outer layer. In such an embodiment, both edges of the two layers are visible on the surface of the weld joint.

[0636] like Figure 58A and Figure 59AAs shown, the overlapping layer 2235 of the spacer fabric has an overlapping region 2265 that overlaps with a portion 2160 of the headgear to be welded to the two layers of spacer fabric. The lower overlapping layer 2237 of the spacer fabric has an overlapping region 2267 that overlaps with a portion of the headgear to be welded to the two layers of spacer fabric. The width 2251 of the overlapping region 2265 of the overlapping layer 2235 is greater than the width 2252 of the overlapping region 2267 of the lower overlapping layer 2237 of the two layers of spacer fabric. Therefore, the weld includes a first region 2250A formed by the two layers 2235, 2237 of the spacer fabric and the portion 2160 of the headgear and a second region 2250B formed by one layer 2235 of the spacer fabric and the portion 2160 of the headgear, as described above.

[0637] A weld formed from a single layer of spacer fabric can have less welding (melting and solidification) material and is therefore likely to be more flexible and less brittle than a weld formed from two layers of spacer fabric. Therefore, a weld including two layers of spacer fabric in a portion 2250A of the weld width 2250 and one layer of spacer fabric in the remaining portion 2250B of the weld width can be more flexible and / or less brittle than a weld with two layers of spacer fabric throughout the full width 2250. Thus, a weld including one layer 2235 of spacer fabric overlapping the edge 2237A of another layer 2237 of spacer fabric can provide improved strength compared to a weld including two layers of spacer fabric throughout its full width. Figure 59B This demonstrates the weld seam once the welding process (e.g., RF welding) is complete. The weld seam width 2250 is determined by the width 2251 of the overlap region 2265 of the outer layer 2235 of the spacer fabric that overlaps with the portion 2160 of the headgear. The width 2251 of the overlap region 2251 of the outer layer overlapping with the portion of the headgear can be selected to ensure that the weld seam is prepared to have sufficient peel strength. However, the bottom or inner layer 2237 of the spacer fabric does not need to overlap with the portion of the headgear as much, because the peel strength of the weld seam is determined by the width 2251 of the outer layer overlapping with the portion of the headgear. Therefore, the width 2252 of the inner layer of the spacer fabric overlapping with the portion of the headgear ( Figure 59AThe outer layer can be smaller than the width of the outer layer overlapping the portion of the headgear to achieve a more flexible and / or less fragile weld without reducing peel strength. Furthermore, another benefit is that the headgear manufacturing process is simplified when the edges of the outer layer of the two spacer fabrics overlap with the edges of the inner layers of the two spacer fabrics, as the edges of each layer of the two fabrics do not need to be aligned. The overlapping outer layer hides the edges of the inner layer, resulting in a clean edge in the weld joint between the two spacer fabrics and the portion of the headgear. In some embodiments, when the headgear is in place on the user's head during use, the outer layer of the two spacer fabrics faces away from the user's face (in other words, the outer layer is the outer layer of the spacer fabrics previously described). This makes the weld visible to the outside of the headgear during use. In some embodiments, the welding material (the material that melts and solidifies) of the joint does not completely penetrate the portion of the headgear material, and therefore the welding material is positioned away from the inside of the headgear that contacts the user's head or face. However, in an alternative embodiment, the outer layer of the spacer fabric may contact the user's head during use.

[0638] To provide users with an aesthetically pleasing appearance and improved comfort, it is preferable to keep the weld width 2250 in the 3D fabric as narrow as possible. However, very narrow welds may tend to break during use, especially when the weld joins the spacer fabric to a headgear section formed of another material, such as foam. Molten foam is very brittle, making very narrow welds prone to breakage. For welding the 3D spacer fabric to the foam material (such as polyurethane foam), the weld width is preferably greater than 3 mm, and preferably from about 3 mm to 6 mm, and most preferably from 5 mm to 6 mm. The strength of the weld is also determined by the weld thickness, which can be defined as a percentage of the thickness of the material to which the spacer fabric is welded (e.g., foam). The foam material in the weld area is very brittle. The greater the weld thickness, the more likely the weld area is to become brittle and less flexible, and therefore the more prone the weld is to breakage. However, the peel strength of the weld increases with increasing weld thickness. Therefore, there exists an optimal weld depth to achieve a weld with a sufficient combination of peel strength and breakage resistance. The optimal weld depth is considered to be 50% to 80% of the thickness of the foam material to which the 3D fabric is welded. Figure 60 The diagram illustrates the trade-off between the tensile strength and peel strength of the weld. Figure 60 In the diagram, the weld strength and weld thickness are displayed as a percentage of material thickness on the x-axis, where P represents peel strength and T represents weld tensile strength (resistance to breakage). The optimal weld thickness is represented by a window covering the intersection of the weld's peel strength and tensile strength.

[0639] Below are some exemplary dimensions for providing improved welds for headgear. In some embodiments, the spacer fabric may have a thickness of about 3 mm (the combined thickness of the two layers is about 6 mm), and the portion (e.g., the periphery of the rear panel) may be formed of a breathable foam and fabric laminate with a thickness of about 4 mm. The outer layer of the spacer fabric may overlap the breathable foam and fabric laminate by about 4 mm to 6 mm. The inner layer of the spacer fabric may overlap the breathable foam and fabric laminate by about 3 mm to 4.5 mm. The outer layer of the spacer fabric may overlap the inner layer of the spacer fabric by about 1 mm to about 2.5 mm. The total weld width, defined by the degree of overlap between the outer layer and the breathable foam and fabric laminate, is about 4 mm to 6 mm.

[0640] Figures 61 to 67 This invention demonstrates a headgear arrangement with a back panel made of 3D fabric sewn to a peripheral portion formed of a foam and fabric laminate. The headgear arrangement reduces or suppresses both seam gathering and 3D fabric gathering along the joint. Preventing seam and 3D fabric gathering ensures a clean and aesthetically pleasing appearance at the joint and that the headgear arrangement is comfortable when worn by the user. Figure 61 and Figure 62 As shown, the headgear arrangement includes a back panel 2301 and a peripheral portion 2302. The peripheral portion includes an upper strap 2152, a top strap 2154, and a lower strap 2156. The back panel 2301 and the peripheral portion 2302 are sewn together along a back-and-forth stitch 2305 along the joint 2303. In some configurations, other variations of the back-and-forth stitch may also be used.

[0641] It is generally difficult to stitch materials with different mechanical properties together. As a non-limiting example, stitching together two materials with different material structures (such as 3D fabric and more rigid foam and fabric laminates) may result in the aforementioned coalescence problem because the differences in material structure lead to different properties (i.e., flexibility, compressibility, stiffness, etc.).

[0642] Similarly, as another non-limiting example, the aforementioned pull-up problem may also occur when 3D fabric is sewn together with plastic-based or internally molded headband straps (which are more rigid than 3D fabric). That is, in some configurations, when 3D fabric is joined to the plastic-based portion of the headband, pull-up may occur due to differences in properties caused by the material construction (i.e., flexibility, compressibility, stiffness, etc.).

[0643] Alternatively, as a non-limiting example, the aforementioned cohesion problem may also occur when two materials with similar material constructions but different mechanical properties (such as a foam and fabric laminate with a density of 7 pounds and a foam and fabric laminate with a density of 10 pounds (which is more rigid than 7 pounds)) are sewn together, because the difference in mechanical properties, despite having similar material constructions, results in different properties (i.e., flexibility, compressibility, stiffness, etc.).

[0644] Typically, between rigid and non-rigid materials, more rigid materials maintain their shape under seam tension, while less rigid materials are prone to deformation and twisting under the tension applied by the seam. Therefore, sewing a back panel formed of 3D fabric to a perimeter portion formed of foam and fabric laminate can cause the seam and 3D fabric to bunch together. This bunching of the seam and 3D fabric (i.e., the back panel) results in an unsightly appearance that is neither aesthetically pleasing nor appealing to the user. Furthermore, this bunching can also lead to loosening of the joint, preventing the back panel and perimeter portion from being securely fastened together. To illustrate, Figures 68 to 71 The seam 2305 is depicted as gathering along the joint 2303 between the rear panel 2301 and the peripheral portion 2302.

[0645] Besides differences in material configuration and / or mechanical properties of the back panel and surrounding portions, the shape of the back panel can also affect the gathering of the seams and fabric. More specifically, a back panel with corners forming sharp angles may cause the seams to gather at the corners. To illustrate, Figure 68 and Figure 69 The back panel 2301 is shown, having upper corners 2304 formed at angles of less than 45 degrees and 30 degrees, respectively. As shown, the upper corners 2304 narrow rapidly, leaving little material available for the stitching 2305 that will be sewn through the back panel 2301. Figure 70 This is a close-up view showing the reduction in the width of the seam 2305 at the end of the joint 2303. As shown, the sharp upper corner 2304 of the back panel 2301 provides less usable material for the seam 2305 through which the sewing will be performed. Accordingly, the width of the seam 2305 is also reduced, causing the seam 2305 to converge. Therefore, the width of the seam 2305 decreases at the end of the joint 2303. That is, the narrowing width of the upper corner 2304 of the back panel 2301 causes the width of the seam 2305 to also narrow. Thus, the reduced width of the seam 2305 causes the seam 2305 to converge at the end of the joint 2303.

[0646] Figure 71The diagram illustrates the gathering of the 3D fabric of the back panel 2301 caused by the combination of the sharp angle at the upper corner 2304 of the back panel 2301 and the greater compressibility of the 3D fabric back panel 2301 relative to the foam and fabric laminated periphery 2302. As shown, the seam indicated at 2306 is sewn onto the edge 2344 of the sharp upper corner 2304 of the back panel 2301, which is consistent with... Figure 70 Similarly. However, because the 3D fabric back panel 2301 is more compressible than the foam and fabric laminate periphery 2302, the upper corner 2304 of the back panel 2301 is compressed and deformed under the tension of the seam 2305, while the foam and fabric laminate material of the periphery 2302 remains unchanged. It should be noted that, for illustrative purposes, in Figure 70 The rear panel 2301 and the surrounding portion 2302 are presented as if they were formed of the same material or a material with similar mechanical properties. Compression causes the 3D fabric at the upper corner 2304 of the rear panel 2301 to gather and combine with the gathered seam to create a lump or pressure point that embeds into the user's head and causes discomfort. The compression of the 3D fabric also further reduces the width of the seam 2305, thereby further increasing the gathering of the seam 2305.

[0647] In comparison, Figures 61 to 67 A back panel 301 formed of 3D fabric is shown, which is stitched to a peripheral portion 2302 formed of a foam and fabric laminate by seam 2305, where the seam does not gather along the joint 2303 and the 3D fabric does not gather. More specifically, the seam 2305 has a generally consistent width over the entire length of the joint 2303, such that the seams are substantially evenly spaced on both sides of the joint 2303 between the back panel 2301 and the peripheral portion 2302. The generally consistent seam width reduces seam gathering and 3D fabric gathering along the joint 2303. A generally consistent seam width can generally be defined as having a repeatable pattern within standard manufacturing tolerances along a straight length. Those skilled in the art will understand that seams along curves can have a smaller seam width inside the curve than outside the curve.

[0648] As shown in one non-limiting embodiment, Figure 61 and Figure 62 A rear panel 2301 with a generally inverted isosceles trapezoidal shape is shown, the rear panel including a top edge, a bottom edge, and lateral edges connecting the top edge to the bottom edge. That is, the rear panel 2301 has four sides, each of which may be linear or curved, a set of opposite sides having one relatively long side and one relatively short side, and a second set of opposite sides having approximately equal lengths. The rear panel 2301 is symmetrical across a vertical centerline, as shown... Figure 62 As shown. In some configurations, the posterior panel 2301 has a generally inverted isosceles trapezoidal shape. The trapezoidal shape is configured to follow the contours of the user's upper neck and lower cranial region. That is, the top edge is positioned slightly below the user's occipital lobe, while the bottom edge is positioned on the user's neck. Therefore, the top edge of the posterior panel 2301 is wider than the bottom edge, and the lateral edges extend laterally outward from the bottom edge toward the top edge (relative to the vertical centerline) to accommodate the increased width of the user's occipital bone relative to the user's neck. The top edge of the posterior panel can be bent to accommodate the shape of the user's occipital lobe.

[0649] Those skilled in the art will understand that the rear panel 301 is not limited to a generally inverted isosceles trapezoidal shape with four sides. In some configurations, the geometry of the rear panel 2301 may include other quadrilateral or polygonal shapes. Furthermore, the length, shape, and curvature of the top, bottom, and side edges of the rear panel 2301 may vary depending on the size, shape, and geometry of the user's head.

[0650] Figure 63 The back panel 2301 is shown in its folded and unstitched state. The back panel 2301 comprises a single layer of 3D fabric 2330 folded along a folding region 2332. When folded, the folding region 2332 provides a pleated edge 2336 that provides a natural and soft edge to the back panel 2301 that comfortably rests against the user's neck. Similar to... Figure 47B The back panel 2201 of the 3D fabric 2330 has a front side 2340 and a back side 2342. When the inside of the 3D fabric 2330 is turned out (i.e., the back side 2342 of the fabric faces outward), the free ends 2334 of the 3D fabric 2330 are joined together to form a hollow tubular shape. The free ends 2334 are sewn together to form a seam allowance 2338 opposite to the folded area 2332. When the inside of the 3D fabric 2330 is turned out, the seam allowance extends radially outward from the center of the tubular 3D fabric 2330.

[0651] During assembly, the 3D fabric 2330 is then flipped face-out, so that the front side 2340 faces outward and the back side 2342 faces inward, as shown below. Figure 64 As shown. Therefore, the seam head 2338 extends radially inward toward the center of the tubular 3D fabric 2330. That is, the seam head 2338 is located in the hollow cavity of the back panel 2301.

[0652] The free ends 2334 of the 3D fabric 2330 can be sewn together by a seam (not shown) to form a tube. In some configurations, the seam can be formed by sewing straight, zigzag, or overlock stitches. When the right side of the 3D fabric 2330 is turned outwards, the seam forms the seam edge 2344 of the back panel 2301. Similarly, when the right side of the 3D fabric 2330 is turned outwards, the folded area 2332 forms a folded edge 2336, similar to... Figure 58B The folded area 2310 is thus formed. Therefore, seam 2344 forms the top edge of the rear panel 2301, while fold 2336 forms the bottom edge of the rear panel 2301. In other configurations, the seam may be formed by gluing, adhesives, welding, etc., instead of sewing.

[0653] like Figures 63 to 65 As shown, the back panel 2301 has a lateral edge 2350 extending between a folded edge 2336 and a seam edge 2344. The lateral edge 2350 has a curved profile shape having a convex region 2352 and a concave region 2354. The convex region 2352 (i.e., curved outwards relative to the centerline of the back panel 2301) connects to and / or extends toward the seam edge 2344. The concave region 2354 (i.e., curved inwards relative to the centerline of the back panel 2301) connects to and / or extends toward the folded edge 2336. The convex region 2352 transitions into the concave region 2354 at an inflection point 2356. The inflection point 2356 is located below the seam allowance.

[0654] The lateral edge 2350 at the convex region 2352 has a curved shape, such that the lateral edge 2350 intersects the seam edge 2344 at approximately a right angle. The seam edge 2344 curves upward toward the upper edge 2360 of the peripheral portion 2302 and extends away from the center of the rear panel 2301. Therefore, in order to form a right angle with the seam edge 2344, the lateral edge 2350 extends away from the center of the rear panel 2301 within the concave region 2354 (from...). Figure 64 The center line shown transitions to extend toward the center of the rear panel 2301 in the convex region 2352. That is, the lateral edge 2350 in the convex region 2352 extends toward the center of the rear panel 2301 to form a right angle with the upward and outward extending seam edge 2344.

[0655] like Figure 65 As shown, the intersection of the lateral edge 2350 and the seam edge 2344 forms an angle of approximately 90 degrees. Figures 68 to 71 Compared to the sharp angle of the upper corner 2304, the intersection of the seam edge 2344 and the side edge 2350 provides more material and space on both sides of the joint 2303 for the sewing 2305 to pass through the 3D fabric. For example... Figure 62As shown, the width of the seam 2305 remains generally consistent, and the seam 2305 spans the entire length of the joint 2303. Figure 67 This is a close-up view of the seam 2305 at the upper corner 2304. As shown, the seam 2305 has a seam width Ws that is distributed approximately evenly on the joint 2303, such that approximately half of the seam width Ws / 2 is on each side of the joint 2303 and extends into each of the rear panel 2301 and the peripheral portion 2302.

[0656] Therefore, the substantially 90-degree angle between the convex region 2352 of the lateral edge 2350 and the seam edge 2344 allows the seam 2305 to end substantially uniformly between the rear panel 2301 and the peripheral portion 2302. The width of the seam 2305 does not decrease at the end of the joint 2303, and does not cause the seam 2305 to converge at the end of the joint 2303. Thus, compression and deformation of the rear panel 2301 at the upper corner 2304 are prevented or suppressed. Similarly, the reduction in the width of the seam 2305 at the end of the joint 2303 is also prevented or suppressed.

[0657] and Figure 68 Compared to a rear panel 2301 with straight lateral edges, the substantially 90-degree angle between the lateral edges 2350 and the seam 2344 results in the upper portion of the rear panel 2301 being wider between the lateral edges 2350 at the convex region 2352. Due to the increased width of the convex region 2352, the concave region 2354 allows the lateral edges 2350 to adapt to the width of the convex region 2352, while also narrowing towards the folded edge 2336, allowing the rear panel 2301 to accommodate the narrower width of the user's neck.

[0658] like Figure 66 As shown, the peripheral portion 2302 may have a corresponding recessed region 2358 defined by the receiving edge 2362, the recessed region having an inward or concave shape corresponding to the convex region 2352 of the lateral edge 2350. That is, the receiving edge 2362 has a shape that matches the convex region 2352 and concave region 2354 of the lateral edge 2350 of the rear panel 2301. Therefore, the recessed region 2358 receives the upper corner 2304 of the rear panel to provide a neat and aesthetically pleasing appearance.

[0659] In addition, such as Figure 64 and Figure 65 As shown, the upper edge 2360 of the peripheral portion 2302 forms a substantially continuous curve with the seam edge 2344 of the rear panel 2301. Therefore, since the notch region 2358 of the peripheral portion 2302 has a shape corresponding to the upper corner 2304 of the rear panel 2301, the receiving edge 2362 of the peripheral portion 2302 also forms a substantially perpendicular angle with the upper edge 2360, as shown. Figure 66 As shown. Similar to the back panel 2301, the substantially 90-degree angle (as opposed to a sharp acute angle) between the upper edge 2360 and the receiving edge 2362 of the peripheral portion 2302 provides material and space on the peripheral portion 2302 to allow the seam 2305 to be fully formed within the fabric and to terminate substantially uniformly between the back panel 2301 and the peripheral portion 2302. In other configurations, the upper edge 2360 and the receiving edge 2362 of the peripheral portion 2302 may form an angle of less than 90 degrees. This is because the peripheral portion 2302 is formed of a foam and fabric laminate material (e.g., neoprene or Breath-O-Prene) that is more rigid than the back panel 2301 (i.e., 3D fabric), and the peripheral portion 2302 is less compressed by the seam 2305 compared to the back panel 2301.

[0660] The lateral edge 2350 of the back panel 2301 extends a distance away from the seam edge 2344 of the back panel 2301 in a direction perpendicular to the seam edge 2344, such that the inflection point 2356 is located below the seam allowance 2338, as shown. Figure 64 As shown. In some configurations, the convex region 2352 of the lateral edge 2350 has a radius of curvature larger than the seam width Ws, which further prevents the seam from converging along the convex region 2352. In other configurations, the convex region 2352 may have a radius larger than the length of the seam allowance 2338 (i.e., the distance between the seam edge 2344 and the free end 2334). Furthermore, the widest distance between the lateral edges 2346 of the seam allowance 2338 is smaller than the widest distance between the lateral edges 2350 of the back panel 2301 within the convex region 2352. Therefore, the lateral edges 2346 of the seam allowance 2338 do not extend beyond the lateral edges 2350 of the back panel 2301, such that the convex region 2352 completely covers the seam allowance 2338 and the seam allowance 2338 is completely contained within and enclosed within the back panel 2301. In other words, the lateral edge 2346 of the seam allowance 2338 is positioned laterally inside the lateral edge 2350 of the rear panel 2301. Therefore, when the rear panel 2301 and the peripheral portion 2302 are sewn together by the seam 2305, the seam allowance 2338 does not extend beyond the joint 2303, so that the seam 2305 is sewn beyond the seam allowance 2338. The seam on the seam allowance 2338 (e.g., Figure 68 and Figure 69(As shown in the back panel 2301) This results in a hard lump or pressure point in the upper corner 2304 of the back panel 2301, which can embed into the user's head and cause discomfort. In some configurations, the lateral edge 2346 of the seam allowance 2338 is positioned laterally inside the seam 2305, so that no part of the seam allowance 2338 is sewn over. Therefore, the seam 2305 will have a more uniform thickness, flexibility, stiffness, etc., along its entire length. Furthermore, having the edge 2346 of the seam allowance 2338 contained within the cavity of the back panel 2301 and not hanging over the joint 2303 prevents or suppresses the exposure of the seam allowance 2346, which would result in an untidy appearance and could also cause the ends of the fabric to fray.

[0661] Those skilled in the art will understand that the angle between the seam edge 2344 and the side edge 2350 is not limited to 90 degrees, and may include angles less than or greater than 90 degrees, provided that sufficient material is provided to allow the seam to end substantially uniformly between the back panel and the perimeter portion so that seam and / or material convergence does not occur. The minimum or maximum angle between the seam edge 2344 and the side edge 2350 may depend on the width, length, and type of the seam, the type of material to be joined, the shape of the back panel and the perimeter portion, etc.

[0662] Figure 72 An alternative configuration for the rear panel 2401 is shown (indicated by a longer dashed line), compared to Figure 62 The rear panel 2301 (shown in solid lines) has a convex region 2452 on its lateral edge 2450 extending outward a greater distance from the end of the seam 2444 of the rear panel 2401. Relative to Figure 62 In the rear panel 2301, the convex region 2452 has a larger radius of curvature and a lower inflection point 2456. An alternative configuration of the rear panel 2401 provides additional distance between the lateral edge 2450 of the rear panel 2401 and the seam allowance 2438 (shown as a shorter dashed line), so that the stitch (not shown) overlaps less or not at all with the overlapping seam allowance 2438.

[0663] Figure 73 and Figure 74 An alternative arrangement of the back panel and surrounding portions is shown, offering a different aesthetic while maintaining a clean joint finish. In this alternative arrangement, the lateral edges of the back panel 2501 are linear towards the fold 2536, while they are convex towards the seam 2544. The linear region 2554 transitions into the convex region 2552 at the cut point 2556. The cut point 2556 is below the seam allowance 2538. The linear region 2554 converges towards the fold 2536.

[0664] and Figures 63 to 67The rear panel and the peripheral portion are arranged oppositely. The rear panel 2501 has a seam 2544 that does not form a continuous curve with the upper edge 2560 of the peripheral portion 2502. That is, the intersection of the seam 2544 and the upper edge 2560 forms a corner. Therefore, the upper corner 2504 of the rear panel and the upper corner 2564 of the peripheral portion also form a corner. The upper corner 2504 of the rear panel has an angle close to 90 degrees. The angle prevents the seam and seam from converging and compressing the upper corner 2504. The upper corner 2564 of the peripheral portion has an angle β greater than 90 degrees. In some configurations, the angle... It can be between 70 degrees and 120 degrees. Preferably, the angle β is greater than 70 degrees. Since the material of the peripheral portion 2502 (i.e., the foam and fabric laminate) is unlikely to be compressed and twisted under the tension and pressure of the seam, the angle β can be less than 90 degrees.

[0665] The rear panel 2501 has a trapezoidal shape that is symmetrical across the vertical center line, such as... Figure 74 As shown, the folded edge 2536 and the seam edge 2544 define the top and bottom edges of the back panel 2501. The folded edge 2536 and the seam edge 2544 define a first width W1 and a second width W2, respectively. As shown, the first width W1 is smaller than the second width W2. That is, the back panel 2501 has a top edge that is wider than the bottom edge.

[0666] The distance between the lateral edges 2550 of the convex region 2552 defines a third width W3, which is the widest point of the rear panel 2501. The corner of the free end 2534 of the seam allowance 2538 defines a fourth width W4. The fourth width W4 is smaller than the third width W3, such that the seam allowance 2538 does not extend beyond the lateral edges 2550 of the rear panel 2501. Furthermore, the convex region 2552 of the lateral edge 2550 extends outward from the end of the seam edge 2544 of the rear panel 2501, such that the tangent point 2556 is located below the seam allowance 2538, and when the front side of the rear panel 2501 is turned outward, the convex region 2552 completely covers the seam allowance 2538. Therefore, when the rear panel 2501 and the peripheral portion 2502 are sewn together (sewing not shown), the seam allowance 2538 does not extend beyond the joint 2503, causing the stitching to extend beyond the seam allowance 2538. Thus, the stitched joint 2503 will have substantially uniform hardness, flexibility, etc. along the entire length of the joint 2503.

[0667] Those skilled in the art will understand that the techniques described above for preventing seam and / or fabric clumping are not limited to bonding 3D fabrics and foam / fabric laminates. These techniques can be used to bond any material or a combination of materials with different material structures and / or mechanical properties. Similarly, these techniques can also be used to bond components formed of the same material, wherein the material has low stiffness, density, hardness, etc., and is prone to clumping.

[0668] VI. Additional terms

[0669] Unless the context clearly requires otherwise, the words “comprise,” “comprising,” etc., used throughout this specification and claims are to be interpreted in a sense of inclusion (as opposed to exclusion or extensibility), that is, meaning “including but not limited to.” Conditional language such as, in particular, “can,” “could,” “might,” or “may,” unless otherwise expressly stated or otherwise understood in the context of use, is generally intended to convey that certain embodiments include certain features, elements, and / or steps while others do not. Therefore, such conditional language is not generally intended to imply that features, elements, and / or steps are required by any means in one or more embodiments, or that one or more embodiments, with or without user input or prompting, must include logic for determining whether such features, elements, and / or steps are included or performed in any particular embodiment.

[0670] Any reference to prior art in this specification is not and should not be construed as an admission or suggestion in any form that such prior art forms part of the general common sense in any country in the world that is committed to its field.

[0671] This invention can also be broadly defined as the components, elements, and features individually or collectively mentioned or indicated in the specification of this application, and any or all combinations of two or more of the said components, elements, or features. The various features described above can be used independently of each other or can be combined in various ways. All possible combinations and sub-combinations are intended to fall within the scope of this disclosure. Furthermore, certain features may be omitted in some specific embodiments. Any methods and processes described herein are not limited to any particular order, and the actions or steps associated with them may be performed in other suitable orders. For example, the described actions or steps may be performed in an order other than that specifically disclosed, or multiple actions or steps may be combined into a single action or step. Example actions or steps may be performed serially, in parallel, or in some other manner. Features may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently from those described. For example, elements may be added, removed, or rearranged compared to the disclosed example embodiments. Furthermore, the inventions disclosed herein by way of example may be suitably practiced in the absence of any elements not specifically disclosed herein.

[0672] In the above description, reference has been made to components, either as a whole or having known equivalents thereof, which are incorporated herein as if presented separately.

[0673] It should be emphasized that many variations and modifications can be made to the above embodiments, and the elements of the embodiments should be understood as acceptable instances, etc. All such modifications and variations are intended to be included within the scope of this disclosure. The foregoing description details certain embodiments of the invention. However, it should be understood that the invention can be practiced in many ways, regardless of the detail of the foregoing description. Also as stated above, it should be noted that the use of specific terms in describing certain features or aspects of the invention should not be construed as implying that the terms are redefined herein to include any specific feature associated with the term. Therefore, the scope of the invention should be understood in accordance with the appended claims and any equivalents thereof.

Claims

1. An anti-asphyxiation valve for a breathing mask, comprising: A conduit, comprising a first end, a second end, and a port located on one side of the conduit between the first end and the second end, the first end being configured to receive a gas flow from a gas source, and the second end being coupled to the breathing mask; and A valve baffle assembly, the valve baffle assembly including a support and a valve baffle pivotally connected to the support, Specifically, when the support member of the valve baffle assembly is connected to the conduit and when the valve baffle is in the first position, the valve baffle at least partially blocks the port and allows gas entering the first end of the conduit to flow to the second end of the conduit. And when the baffle is in the second position, the valve baffle at least partially blocks the first end of the conduit, causing exhaled gas entering the second end of the conduit to flow from the second end through the port to a location outside the conduit. The valve baffle includes an elongated beaded edge extending from the valve baffle and configured to contact a portion of the inner wall of the conduit surrounding the port when the baffle is in the first position, so as to space the valve baffle from the inner wall of the conduit. The elongated beaded edge includes at least one tapered portion, the at least one tapered portion being configured such that, when viewed from the side, at least a portion of the elongated beaded edge extends further from the valve baffle than another portion of the beaded edge.

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