Headgear for patient interface

Abstract

Disclosed is headgear for a patient interface, the headgear including first and second overlapped panels. The overlapped panels define an overlap region where the first and second panels overlap above and below one another, respectively. The overlapped panels also define a non-overlapping region where the first panel does not overlap. In the overlap region, adjacent surfaces of each overlapped panel are fused together.

Description

[Technical field]

[0001] The present invention relates to headgear for a patient interface. [Background technology]

[0002] Respiratory interfaces or masks are used to provide one or more respiratory gases, such as, for example, air in CPAP therapy, including, for example, VPAP and BiPAP systems, or NIV, or high flow therapy.

[0003] The respiratory interface may include a nasal, oral or full face, i.e., both nasal and oral interface. Thus, the interface may be an indirect interface, such as an indirect interface that covers the nose, mouth or both, or an interface that includes a nasal nozzle or pillows or the like that goes into the wearer's nose.

[0004] Headgear for the respiratory interface may include at least two side straps that, in use, extend from the rear of the headgear along the left and right sides of the patient's head and connect to the interface. Other configurations may include two sets of upper and lower side straps on each side.

[0005] The headgear may include an upper strap, such as a top strap or a forehead strap, and the respiratory headgear may be in a variety of other forms. For example, the headgear may include only a crown or forehead strap or a back loop and a single strap on either side of the patient's head or face connected to the mask. Typically, the length of one or more of the headgear straps may be adjustable, so that the patient can don the interface and headgear when the headgear strap or straps are loose, tighten the strap when the interface and headgear are in place, and then securely hold the mask and headgear in place until removed or doffed.

[0006] Patients may use various types of respiratory interfaces or masks to deliver various respiratory therapies. In order to deliver respiratory therapy to a patient, the interface must be held in some manner over the patient's mouth and / or nose. This is especially true when the respiratory therapy involves the delivery of pressurized gas, and the interface must be held against the patient's face to ensure at least some degree of seal and to prevent undesired leakage of the respiratory therapy gas around the interface. Headgear may be utilized to provide the functionality of holding the interface against the patient's face.

[0007] Respiratory interfaces or masks may be used in a variety of settings, including hospital settings and in the patient's home. Various respiratory therapies may be provided while the patient is either awake or asleep, or both.

[0008] Although the primary function of the headgear is to hold the interface against the patient's face and / or provide a seal with the patient's face to counteract pressure-generating forces, how the headgear transmits forces to the patient's head can greatly affect patient comfort and potentially compliance with respiratory therapy. Weight-bearing parts of the headgear can cause irritation or discomfort. This can be especially true when the interface and headgear are worn for long periods of time, such as when sleeping.

[0009] When using the interface and headgear during sleep, at least some portions of the headgear may be disposed between the patient's head and the bed, which may be uncomfortable for the patient as localized thickness of the headgear may increase the pressure experienced by the patient's head when wearing the headgear.

[0010] Different patients may also have widely differing body sizes, which may include, for example, different head circumferences, different face and skull shapes, different tissue depths and sensitivity in different regions, etc. This may be exemplified at the back of a patient's head, where some patients have muscular necks or necks that extend farther from the skull, while other patients have more fatty tissue or necks that do not extend farther from the skull. Such differences may result in different levels of fit or comfort for different patients with a given headgear. Summary of the Invention [Problem to be solved by the invention]

[0011] Although the headgear can be adjusted in some way to fit different patients, for example by shortening or lengthening one or more of the straps, such adjustments may not adequately compensate for anatomical differences between patients. Such adjustments may additionally or alternatively not provide sufficient support, or at least a sense of support, of the headgear on the patient's head. Ideally, the headgear is not only adjusted to comfortably fit the patient's anatomy, but also fits securely and closely to the patient's head in the adjusted state.

[0012] In addition to accommodating various patient constraints, it may be desirable for the headgear to serve various secondary functions in addition to holding the interface on the patient's face. For example, it may be desirable for the headgear, while holding the interface on the patient's face, to enable a "pull away" function that allows the user to pull the interface away from contact with the face. This may allow the patient to speak to someone more clearly or may provide a short respite from therapy.

[0013] The headgear itself may have specific local requirements for its structure and function. For example, some areas of the headgear may be subjected to greater loads than other areas in order to hold any given respiratory interface with a certain amount of force. There may also be location-specific needs for stiffness, flexibility, softness or any number of other properties.

[0014] Conventional headgear is generally constructed from one or more joined sections of a laminate including an outer fabric layer sandwiching an inner foam layer, such as a natural or synthetic rubber foam. Pieces of the headgear are cut from sheets of the laminate and then connected to each other or to other components to form the headgear.

[0015] An example of such a laminate material used in the construction of headgear is Breathe-o-prene®. When headgear is made from joined sections of existing laminate materials such as Breathe-o-prene®, the headgear will have a thickness of at least three or more layers that make up the laminate. At the joints between the sections of the laminate, the headgear will have the thickness of both sections that are joined. Even if efforts are made to reduce the thickness of each laminate layer, overlapping laminate sections can easily result in undesirably thick areas and thus a potential source of discomfort for the headgear wearer. For example, if the laminates each have three layers, the resulting joint will have a total combined thickness of six layers.

[0016] Foam materials can deteriorate over time and lose properties such as stretch recovery. [Means for solving the problem]

[0017] In accordance with the present disclosure, headgear may be formed by a first panel and a second panel overlapped together to define an overlap region and fused together at the overlap region.

[0018] One or both of the first and second panels may be partially unoverlapping by the other, thus defining one or more non-overlapping regions of the headgear.

[0019] The panels may be single-ply panels because the headgear may be formed from individual panels including a single ply of one material or a composite of one material, rather than from a bonded laminate of multiple layers of different materials. In a non-overlapping configuration, the headgear includes only the thickness of one single-ply panel, rather than at least three plies, as would be the case if a three-ply laminate material such as Breathe-o-prene® were used. This allows for a relative reduction in thickness.

[0020] The panel may additionally or alternatively be a multi-ply panel, for example a panel constructed of multiple layers or plies of the same or different materials.

[0021] In an overlap configuration, the headgear of the present disclosure can have a reduced thickness or thickness of only two panels compared to six panels when two three-ply laminate materials, such as Breathe-o-prene®, are joined together.

[0022] The panels may be cut to their respective desired shapes and then overlapped and joined together. Such a construction may differ from traditional methods, such as with laminate materials such as Breathe-o-prene®, where headgear is constructed by cutting pre-laminated panel sections and joining them to form the headgear or parts of traditional headgear.

[0023] According to the present disclosure, headgear can be formed with non-overlapping portions, where the headgear includes a single panel that is not overlapped by another panel. This configuration differs from traditional headgear construction methods, such as using cut sections of Breathe-o-prene®, where the headgear always includes at least one three-ply fabric and foam laminate.

[0024] The headgear panels may be cut to shape before being overlapped and joined together.

[0025] In some forms, at least some portions of the headgear may additionally or alternatively be cut after being overlapped over one another, possibly after one or more overlapping portions have been joined together.

[0026] The potential reduction in the number and thickness of panels in both overlapping and non-overlapping configurations of the headgear of the present disclosure, when compared to conventional headgear made from bonded laminate or multi-ply materials, may result in either a localized or overall reduction in headgear thickness. Reduced thickness, whether in a specific location or throughout the headgear, may provide the patient with a visual and / or physical perception of reduced bulk. Reduced thickness may also provide increased comfort for the patient wearing the headgear.

[0027] Any such reduction in the number of panels present at different locations on the headgear and their thickness may provide a corresponding reduction in the overall weight of the headgear.

[0028] The panel may exclude foam materials.

[0029] Headgear according to the present disclosure may be fused, such as by welding.

[0030] Conventional headgear laminates that include foam layers are not traditionally fused together by welding because welding reduces the cellular properties of the foam and compresses it into a rigid form, and thus welding of conventional headgear is limited to welding the perimeter edges of the panels or the edges of the overlap areas.

[0031] Headgear according to the present disclosure may eliminate one or more foam layers, and the panels may be fused to one another over a substantial portion or all of their overlap regions, e.g., at least a relatively wide border around the periphery of the overlap region may be fused more than in conventional laminated headgear.

[0032] The partial or total elimination of foam materials such as Breathe-o-prene® may allow for the use of different panel materials than are required to cover the foam layer, which may allow for the use of lower cost, thinner, and lighter panel materials, for example.

[0033] The headgear of the present disclosure may utilize lightweight, thin woven panels, so that the overall thickness, and thus the bulk and weight, of the resulting headgear may be reduced, especially as compared to conventional headgear constructed from laminated foam.

[0034] Headgear according to the present disclosure may utilize fusion bonding to provide desired characteristics of the headgear.

[0035] By fusing over a wider path or over a wider area, rather than attempting to fuse only a minimal area, particularly at the periphery of the overlapping panels, it may be possible to minimize the narrow features in which the panels are fused together by welding, thereby reducing the associated problems with arcing and seizing that can occur when welding in narrow features.

[0036] The two overlapping panels may be fused to one another around at least the periphery of the overlap area.

[0037] The two overlapping panels may be fused to one another around at least the border of the overlap area.

[0038] The two overlapped panels of the rear portion for the headgear may be fused together around the entire periphery of the overlapping region, except for one or more strap connection portions of the rear portion. If one or more strap connection portions of the rear portion are left unfused during the manufacture of the rear portion, they may be fused thereafter during the manufacture of the headgear. For example, a strap may be interposed between the unfused first and second panels at the or each strap connection region, and the assembly may then be fused. With such a configuration, at least the entire periphery of the overlapping region of the two first and second panels may be fused together, where they are directly fused together at the portions other than the strap connection portions, and indirectly fused together at the strap connection portions by being fused to the interposed strap portions.

[0039] The two overlapping panels at the rear portion of the headgear may be fused to one another over their entire overlapping area, except for one or more strap connection portions, where a portion of a strap is interposed between the overlapping first and second panels, and where the first and second panels are each fused to the strap.

[0040] The two overlapping panels of the headgear may be fused to each other over the entire overlapping region, apart from one or more pocket forming regions of the overlapping panels. An insert such as a strap end may be provided in the pocket in the pocket forming region before the overlapping panels are fused to each other. Alternatively, an insert may be provided in the pocket through the opening after the overlapping panels are fused to each other. Once the insert is provided in the pocket, the overlapping panels and the insert may be fused to each other or may remain unfused.

[0041] The two overlapping panels may be fused together from a first edge of the overlap area to an opposing edge of the overlap area.

[0042] The two overlapped panels may be fused to one another over the entire overlap area, apart from a small area within the interior of the overlap area.

[0043] The two overlapping panels may be fused to one another over substantially the entire overlap area.

[0044] The two overlapping panels may be fused to one another over the entire overlap area.

[0045] The two overlapping panels may be fused together by full surface fusing of the panels in the overlap area.

[0046] The two overlapping panels may be fused together such that the majority of the length along a line between the two edges of the overlap region is fused.

[0047] Two overlapping panels may be fused together such that the majority of the length along any line between the two edges of the overlap region is fused.

[0048] A majority can be anywhere from barely a majority to the whole.

[0049] Reference to a portion of headgear, such as an edge or overlap region of the headgear, is understood to include any extent along the periphery of that portion.

[0050] In contrast to traditional stitched joints, where it is desirable to minimize seam size to reduce impact on comfort or visibility, panels joined by fusion bonding can be fused to each other over large areas without the corresponding changes in seam bulk or surface finish that large stitched areas would cause.

[0051] When panels are fused together, the entire adjacent surfaces of the fused portions may be connected to one another. When panels are traditionally sewn together, the panels are only connected between each successive seam. Thus, although seams may be provided intimately and even over a large area, the relative fused areas of the panels may provide a greater degree of connection between the panels than a sewn joint. In other words, by fusing, rather than sewing, the panels may be secured to one another for a given area that is fused or sewn together, a relatively large percentage of the area of ​​the adjacent panel faces may be secured to one another.

[0052] Panels, especially woven panels, that are fused over a large portion of the panel may provide the headgear with rigid, yet flexible properties. The fused areas may provide the panel with a visually clean and uniform surface. Selectively fusing or not fusing portions of the panel may allow for different material properties within one or more regions of the same panel. It may also provide differences in surface characteristics of the areas comprised of one or more of the same panels.

[0053] Fabric can be an example of a woven material.

[0054] Where two panels are superimposed to form headgear or part of headgear, both panels may be a textile such as a fabric.

[0055] One or both of the two overlapping panels may be made of or may include a polymeric material.

[0056] One or both of the two overlapping panels may be made of or may include a bipolar material.

[0057] The two panels fused together may be formed into one integral composite panel at the overlap area rather than two separate panels that are adhered or affixed to one another.

[0058] Fusing the panels may offer advantages over other additive methods of joining the panels, such as by stitching or using adhesives, in particular, the weight and potentially thickness of the joined panels may be relatively reduced.

[0059] Forming all or at least a majority of the headgear by fusing its constituent panels, such as by welding, may provide a more cost-effective method of joining the panels than other conventional methods.

[0060] Fuses may additionally or alternatively be applied to the panels in the non-overlapping regions of one or more overlapping panels to modify the properties of the panels.

[0061] Headgear according to the present disclosure having two overlapping panels defining an overlap region may also have one or more non-overlapping regions of one or both of the panels.

[0062] The non-overlapping of one panel may form a boundary around some or all of the other panel. For example, a second panel may be provided entirely within the boundary of a first panel, such that the non-overlapping boundary of the first panel extends around the second panel.

[0063] Headgear according to the present disclosure may have a non-overlapping region around some or all of the periphery of the headgear.

[0064] For example, the headgear may have one or more non-overlapping regions around the periphery of both the upper and lower rear portions of the headgear.

[0065] The non-overlapping areas may be formed by the same panel.

[0066] The non-overlapping region at the upper periphery of the rear portion of the headgear may be provided along a substantially linear periphery of the overlapping region.

[0067] The non-overlapping region at the upper periphery of the rear portion may be of substantially continuous width.

[0068] The non-overlapping region at the lower periphery of the rear portion of the headgear may be provided along one or more curved portions of the overlapping region.

[0069] The non-overlapping region at the lower periphery of the rear portion may vary in width.

[0070] The non-overlapping region at the lower periphery of the rear portion may have an edge with a radius of curvature that is less than the radius of curvature of the adjacent curved portion of the overlapping region.

[0071] The non-overlapping region at the lower periphery of the rear portion may define one or more crescent shapes.

[0072] Headgear according to the present disclosure having first and second overlapping panels defining an overlap region may be fused around the entire perimeter of the overlap region.

[0073] Fusing around the entire perimeter of the overlap region can provide the first and second panels as a single, integral, planar assembly with no free panel edges in the overlap region.

[0074] Headgear according to the present disclosure may have a rear portion including first and second overlapped panels and a non-overlapping area of ​​the first panel that defines at least a portion of the periphery of the rear portion.

[0075] The non-overlapping area of ​​the first panel includes a border.

[0076] The boundaries are located at least at the upper and lower edges of the rear portion when the headgear is worn.

[0077] The border may vary in width around the periphery of the rear portion away from the overlap region.

[0078] The border provides a softening effect on the edges.

[0079] Headgear or a rear portion of the headgear according to the present disclosure having first and second overlapping panels fused to one another at an overlap region of the panels may include two strap connection portions. When the headgear is assembled, the two straps may be connected at their respective strap connections at the rear portion. In this configuration, the overlap region may define a continuous fused zone of the first and second panels between the two strap connection portions. The continuous fused zone of the first and second panels aids in load transfer across the headgear between the straps of the headgear.

[0080] The overlap region may define a continuous fused zone of more than one of the first and second panels between the two strap connection portions.

[0081] When more than two strap connection portions are present and a corresponding number of straps are connected thereto, the overlapping regions can define corresponding continuous fused zones between each one of the straps and another one of the straps.

[0082] When there are more than two strap connection portions, the overlap region may define a single continuous fused zone between each of the straps.

[0083] Headgear according to the present disclosure may have first and second drapeable fabric panels overlapping one another to define an overlap region where the panels are fused to one another at a welded portion of the second panel.

[0084] The weld may be the entirety of the second panel in the overlap region, such that the first and second panels are fused to one another throughout the overlap region.

[0085] The second panel may be entirely overlapped by the first panel.

[0086] The second panel is a weldable fabric.

[0087] The first panel is a non-weldable fabric.

[0088] The second panel and the first panel may each be a weldable fabric.

[0089] The first panel and the second panel may have different stretch characteristics.

[0090] The headgear may further include a strap portion configured to attach to the respiratory interface.

[0091] The first panel and the second panel can define a non-overlapping region, in which the first panel and the second panel overlap one another above and below, respectively, and in which the first panel is not overlapped.

[0092] Where the first panel and the second panel are fused to one another may define a fused zone, and the headgear may have reduced stretchability in the fused zone compared to the non-overlapping area of ​​the first panel.

[0093] In the fused zone, the headgear may have reduced stretchability compared to the unfused portion of the second panel.

[0094] Headgear according to the present disclosure may include first and second drapeable panels overlapping one another to define an overlap region and fused to one another at the overlap region.

[0095] If the panels are fused together, their sagging may be reduced.

[0096] When the panels are fused together, the headgear may have a relatively reduced sag compared to one or more of: a) the sag of the first panel, b) the sag of the second panel, or c) the sag of the unfused portions of the overlap region.

[0097] The first and second panels may be extensible and the fused portion of the overlap region may have a relatively reduced extensibility.

[0098] The first and second panels may be extensible, with the fused portions of the overlap region being relatively non-extensible.

[0099] The first and second panels may be extensible, and the fused portion of the overlap region is non-extensible.

[0100] According to one aspect, the present disclosure provides headgear including a plurality of panels superimposed on one another, the panels being joined to define the headgear by fusing the panels together.

[0101] The panels are fused together by welding.

[0102] The panels are fused together by radio frequency welding.

[0103] Adjacent overlapping surfaces of the panels are fused to one another as well as the peripheral edges of the overlapping portions.

[0104] According to another aspect, the present disclosure provides headgear including a first panel and a second panel overlapped with one another, the headgear being fused over a substantial portion of the overlapped portions of the first panel and the second panel.

[0105] The headgear is fused over a majority of the overlap between the first and second panels.

[0106] The headgear is fused around the entire periphery of the overlapping portion of the first and second panels.

[0107] The headgear is also fused at the non-overlapping portions of either or both of the first and second panels.

[0108] The first and second panels are joined exclusively by fusion bonding.

[0109] The headgear is fused together by radio frequency welding.

[0110] According to another aspect, the present disclosure provides a method of manufacturing headgear for a patient interface, the method comprising: providing a first panel and a second panel partially overlapping the first panel to define an overlap area; applying a weld to the first panel and the second panel; and the step of applying a weld includes applying a weld to the overlap region and beyond a perimeter of the overlap region.

[0111] The step of applying a weld may further include applying a weld to a non-overlapping region of the first panel and / or the second panel, where the panels are not overlapped with one another.

[0112] According to another aspect, the present disclosure provides headgear including a plurality of panels, at least a portion of each panel overlapping at least a portion of another panel, and the overlapping panels being fused together.

[0113] The combination of panels having different properties, the overlapped interfaces between the panels, and the amount, degree or configuration of fused overlaps provide headgear with the potential for location-specific features and characteristics.

[0114] According to another aspect, the present disclosure provides headgear including a first panel and a second panel overlapped with one another to define an overlap area, the first panel and the second panel being fused around a periphery of the overlap area.

[0115] The panels may be fused together around the entire perimeter of the overlap area.

[0116] When the second panel is within the confines of the first panel, the panels may be fused to one another around the entire perimeter of the second panel.

[0117] According to another aspect, the present disclosure provides headgear including two fabric panels superimposed on one another.

[0118] The headgear is comprised of two fabric panels and multiple strap fasteners.

[0119] The two fabric panels are partially fused together.

[0120] The fusion is achieved by welding.

[0121] According to another aspect, the present disclosure provides headgear including two fabric panels superimposed on one another.

[0122] The headgear consists of two fabric panels and multiple strap fasteners.

[0123] The two fabric panels are partially fused together.

[0124] The fusion is achieved by welding.

[0125] According to another aspect, the present disclosure provides headgear including a first panel and a second panel overlapped together to define an overlap area, the first panel and the second panel being fused together around a perimeter of the overlap area.

[0126] According to another aspect, the present disclosure provides headgear including a first panel and a second panel overlapped to define an overlap region, portions of the overlap region away from a periphery thereof being bonded to one another, the bonding being a bonding of one or more materials of the first panel and the second panel to one another.

[0127] The panels are bonded together without stitches or added materials such as adhesives.

[0128] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including first and second overlapped panels defining an overlap region where the first and second panels overlap above and below one another, respectively, and a non-overlapping region where the first panel is not overlapped, and in the overlap region adjacent surfaces of each overlapped panel are fused together.

[0129] The adjacent faces of each panel in the overlap region are fused directly to one another without any intervening material.

[0130] The overlap region includes a fused portion and a non-fused portion.

[0131] The overlap region includes a transition zone between the fused and unfused portions, the transition zone defining the degree of fusion between the unfused and fused portions.

[0132] The transition zone comprises a gradient in the degree of fusion between the fused and unfused portions.

[0133] The majority of the overlap area is fused.

[0134] Substantially the entire overlap region is fused.

[0135] The headgear includes a third panel, and the first panel, the second panel and the third panel define overlapping regions where the first panel is overlapped above and below by the second panel and the third panel, respectively, and adjacent surfaces of the first panel and the second panel and the first panel and the third panel, respectively, are fused to one another.

[0136] The second panel is completely overlapped by the first panel.

[0137] The first panel and the second panel are both stretchable, with the first panel being more stretchable than the second panel.

[0138] The second panel has one or more cutouts defining stretch zones for the first panel within the one or more cutouts.

[0139] The second panel is provided in two or more pieces defining one or more stretch zones of the first panel between the two or more pieces of the second panel.

[0140] When the overlapping panels are fused to one another to define fused zones, the headgear in the fused zones has one or more of reduced stretchability, reduced thickness or smoothed surface compared to headgear in the non-fused zones.

[0141] When the overlapping panels are fused together to define a fused zone, the headgear at the fused zone has reduced stretchability relative to each of the first and second panels.

[0142] When the overlapping panels are fused together to define fused zones, the headgear in the fused zones has reduced stretchability relative to the headgear in the non-overlapping areas.

[0143] The overlap region includes multiple discrete regions of overlapping panels.

[0144] The non-overlapping region includes a plurality of discrete regions of the first panel.

[0145] The headgear may have different material properties or characteristics selected from one or more of sag, stretch, density, surface hardness, surface texture, and thickness. a) The fused portion of the overlapping panels; b) the unfused portions of the overlapping panels; and c) Non-overlapping area of ​​the first panel Each of the above has the same function.

[0146] The headgear in the fused portions includes one or more of higher stiffness, reduced extensibility, less thickness, and a smoother surface texture than the headgear in the unfused portions.

[0147] The non-overlapping region of the first panel is a first non-overlapping region, and the headgear further includes a second non-overlapping region where the second panel is not overlapped.

[0148] The headgear includes different stretch properties for each of the following: The fused portion of the overlapping area, The unfused portion of the overlapping region, and Non-overlapping area of ​​the first panel.

[0149] The adjacent faces of the first and second panels around the periphery of the overlap region are fused together.

[0150] The panels are fused together by heating the material of one or both of the panels.

[0151] The adjacent faces of the first and second panels are fused to one another around the entire periphery of the overlap region.

[0152] The second panel is completely overlapped by the first panel such that the area of ​​the second panel defines an overlap area.

[0153] The second panel is completely overlapped by the first panel, and the adjacent faces of the first and second panels are fused together around the entire perimeter of the second panel.

[0154] The periphery of the second panel is the boundary within the periphery of the overlap area.

[0155] A fusion bond is applied to the second panel along the entire border on both sides of the periphery of the panel.

[0156] The perimeter of the overlap region is the boundary within the perimeter of the overlap region.

[0157] The perimeter of the overlap region includes the borders on either side of the perimeter of the overlap region.

[0158] The width of the border is greater than about 2 mm.

[0159] The width of the boundary is about 2 mm to about 10 mm.

[0160] The border extends beyond the overlap region by at least about 2 mm.

[0161] The border extends beyond the overlap area by at least an amount equal to the predetermined panel placement tolerances during manufacturing.

[0162] Heat is applied across the boundary such that both the first and second panels in the overlap region of the boundary and the or each panel in the non-overlapping region of the boundary are affected by the heat.

[0163] The heating fuses the first and second panels together at the boundary overlap region.

[0164] When the panel is heated, the material properties of the panel change compared to a panel that is not exposed to heat.

[0165] The heating involves melting the material of one or both of the panels.

[0166] The first and second panels in the overlap region are fused together continuously across the overlap region between two or more points at or around the perimeter of the overlap region.

[0167] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including first and second overlapped panels, the overlapped panels defining an overlap region where the first and second panels overlap above and below each other, respectively, and a non-overlapping region where the first panel is not overlapped; The overlapping and non-overlapping regions both include at least one first elasticated zone and at least one relatively reduced second elasticated zone; Each of the at least one second elastic zone is defined by a fused portion of the overlap region, and each of the at least one first elastic zone is defined by a non-fused portion of one or both of the overlap region and the non-overlapping region.

[0168] The fused portions of the overlap region are less stretchable than the unfused portions of the overlap region.

[0169] The fused portions of the non-overlapping regions are less stretchable than the unfused portions of the non-overlapping regions.

[0170] In the first elastic zone, the headgear is more elastic than the headgear in the second elastic zone.

[0171] In the second elasticated zone the headgear is substantially non-elasticated.

[0172] The first layer is a stretch layer and the second layer is a relatively low stretch layer.

[0173] Each of the overlapping and non-overlapping regions includes a stretch zone and a non-stretch zone, respectively.

[0174] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear having a central section including a first layer and a second layer and defining at least one elastic region where the first layer is not overlapped by the second layer and at least one region of reduced elasticity where the first layer is overlapped by the second layer, the elastic regions being located between laterally spaced strap connection portions of the central section.

[0175] The central section has an area of ​​reduced elasticity at its top, and the areas of reduced elasticity connect to the lateral sections of the headgear on either side of the central section.

[0176] One or more areas of reduced elasticity in the central and lateral sections define bands of the headgear.

[0177] The area of ​​reduced elasticity extends beyond the boundary where the first layer is overlapped by the second layer.

[0178] The layer or layers of the headgear in the area or areas of reduced stretch are welded.

[0179] The headgear further includes one or more overlapping elasticated areas where the first layer is overlapped by the second layer, and in each of the one or more overlapping elasticated areas, the headgear is not welded.

[0180] The lateral extent of each lateral region defines one or more strap connection locations.

[0181] Each of the one or more strap connection portions has an increased width relative to a portion of the band in a respective lateral region.

[0182] The one or more strap connection portions each include at least one of one or more overlapping areas of reduced elasticity.

[0183] The headgear has a lateral dimension along the band and a width dimension perpendicular thereto, and in one or both of the lateral sections, the second layer is about 60% to about 95% of the width of the first layer.

[0184] In one or both of the lateral sections, the second layer is about 70% to about 80% of the width of the first layer.

[0185] In one or both of the lateral sections, the second layer is about 80% to about 90% of the width of the first layer.

[0186] The headgear has a lateral dimension along the band and a width dimension perpendicular thereto, and at the lateral intermediate portion of the elasticated region, the second layer is about 20% to about 70% of the width of the first layer.

[0187] At the laterally intermediate portion of the stretchable area, the second layer is about 40% to about 60% of the width of the first layer.

[0188] One or more of the one or more strap connection portions tapers laterally from the strap.

[0189] One or more of the one or more strap connection portions have a triangular shape.

[0190] The one or more strap connection portions include straps, and the strap connection portions and straps are constructed with stretch panels and / or relatively low stretch panels.

[0191] The elasticated area of ​​the center section is located between the band and the two strap connections.

[0192] The overlapping regions are contiguous.

[0193] The non-overlapping regions are contiguous.

[0194] The first layer is of a first stretch value and the second material is of a second, smaller stretch value.

[0195] The first layer is a stretch layer and the second layer is a relatively reduced stretch layer.

[0196] The first layer is a stretchable layer and the second layer is a non-stretchable layer.

[0197] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear having a band portion and a plurality of strap connection portions, and including a plurality of overlapped panels, the headgear defining at least one overlapping region, where at least two of the plurality of panels overlap above and below each other, respectively, and at least one non-overlapping region, where one or more of the plurality of panels are not overlapped by another of the plurality of panels; the headgear is welded to the fused ether adjacent surfaces of the overlapped panels in at least one overlapping region of each; a) the band portion has a first arrangement of welded and unwelded adjacent panel surfaces in one or more overlapping regions within the band; and b) one or more of the plurality of strap connection portions has a second arrangement that differs from the first arrangement of the welded and unwelded adjacent panel surfaces of the one or more overlapping regions within the, or each respective, one or more of the plurality of strap connection portions.

[0198] The first arrangement includes adjacent panel surfaces substantially entirely welded together.

[0199] For example, adjacent panel faces may be welded together except for a small interior area partially of the headgear.

[0200] Adjacent panel faces may be welded together except for those areas that define the desired surface texture.

[0201] The second arrangement includes welded adjacent panel faces having one or more unwelded zones.

[0202] The one or more unwelded zones are located within a boundary from an edge of any overlap region in one or more of the plurality of strap connection portions.

[0203] The border is at least 2 mm.

[0204] The boundary is about 2 mm to about 10 mm.

[0205] The one or more unwelded zones further include one or more spot welds to limit separation of the overlapped panels within the, or each, of the one or more unwelded zones.

[0206] The welded areas of the headgear extend beyond the periphery of each of the at least one overlap area.

[0207] The welded area of ​​the headgear includes a boundary zone of the non-overlapping area adjacent to the overlapping area.

[0208] The width of the boundary is about 2 mm to about 10 mm.

[0209] The border extends beyond the overlap region by at least about 2 mm.

[0210] The border extends beyond the overlap area by at least an amount equal to the predetermined panel placement tolerances during manufacturing.

[0211] The weld in the overlap region includes different material properties than the non-weld in the same overlap region.

[0212] The weld in the non-overlapping region includes different material properties than the non-weld in the same non-overlapping region.

[0213] The headgear further includes a plurality of straps corresponding to the plurality of strap connections, each of the plurality of straps being constructed from one or more of the plurality of overlapping panels.

[0214] The headgear further includes a plurality of straps for connection to respective ones of the plurality of strap connection portions.

[0215] The plurality of panels includes a first panel and a second panel completely overlapped by the first panel, the first panel and the second panel defining an overlapping region and at least one non-overlapping region of the first panel, the overlapping region including the band and at least two of the plurality of strap connection portions, respectively.

[0216] Each of the plurality of strap connections depends from the band.

[0217] At least one pair of strap connection portions extend laterally from the location where the straps are to be connected toward the band.

[0218] The band further includes one or a pair of upper straps.

[0219] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including first and second elastic materials in respective panels at least partially overlapped with one another, the overlapped panels of the first and second elastic materials being joined together at bond regions such that they have reduced elasticity.

[0220] The first stretch material is more stretchable than the second stretch material.

[0221] In the bond areas, the headgear is less elastic than either the first elastic material alone or the second elastic material alone.

[0222] In the bonded areas, the headgear is less elastic than the overlapping first and second elastic materials in the non-bonded areas.

[0223] The low stretch where the overlapping panels are joined together is relatively less stretch than the stretch where the overlapping panels are not joined together.

[0224] In the bonded areas the headgear has less stretch compared to the non-bonded areas.

[0225] In the bond areas the headgear is substantially non-elastic.

[0226] The overlapping panels of the first stretch material and the second stretch material are joined to one another at the bond areas by fusing the panels.

[0227] The overlapping panels of the first and second elastic materials are joined together at the bond area by fusion bonding, whereby one of the materials melts to the other of the materials.

[0228] According to another aspect, the present disclosure provides a method of manufacturing headgear for a patient interface, the method including the steps of: providing a first panel and a second panel, the panels defining an overlap region where the first panel and the second panel overlap above and below one another, respectively, and a non-overlapping region where the first panel is not overlapped; Melting one or both of the panels at the overlap region to fuse the panels together and define a fused zone at the overlap region.

[0229] The method further includes fusing the first panel in the non-overlapping region to define a melt zone in the non-overlapping region.

[0230] The first panel is melted to define a fused zone around the periphery of the overlap region.

[0231] The steps of fusing one or both of the panels in the overlap region and fusing the first panel in the non-overlapping region are provided as a single operation.

[0232] The fusing step or steps include applying heat and pressure to the first and / or second panels.

[0233] The first panel has a first melting point and the second panel has a second melting point, and the one or more melting steps include raising a temperature of at least a portion of the first panel and the second panel above both the first melting point and the second melting point.

[0234] The first melting point is greater than the second melting point.

[0235] The melting step or steps include raising a temperature of at least a portion of the first panel and the second panel to a temperature above the second melting point and below the first melting point.

[0236] The melting step or steps include applying heat and pressure to both the first panel and the second panel, but only the second panel is melted.

[0237] The one or more melting steps may include welding.

[0238] The first panel and the second panel are disposed between the first die and the second die.

[0239] The method further includes moving the first and second dies toward one another.

[0240] The step of moving the first and second dies towards one another comprises one or more melting steps.

[0241] The first die includes a first relatively raised level and a second relatively recessed level, the first level defining one or more molten zones and the second level defining an unfused zone where one or more panels of the headgear are not melted.

[0242] The first die includes a substantially immediate transition between the first level and the second level.

[0243] The first die includes a graduated transition between a first level and a second level.

[0244] The graduated transition of the first die defines a transition zone between the molten and unmolten zones of the headgear.

[0245] The level of the gradual transition of the first die varies linearly between the first level and the second level.

[0246] The gradual transition levels of the palate of the first die follow an S-curve shape.

[0247] The first level and second level define the embossed indicia such that when melted, the headgear includes one or more fused zones and unfused zones that represent the indicia.

[0248] The method further includes cutting one or both of the first panel and the second panel to a predetermined size and / or shape.

[0249] One or both of the dies include a cutting element and the cutting step is combined with the step of moving the first and second dies towards each other.

[0250] The step of fusing one or both of the panels at the overlap region occurs after the two dies are brought together with the first panel and the second panel sandwiched therebetween.

[0251] The step of fusing the first panel in the non-overlapping regions occurs after the two dies are brought together with the first panel and the second panel sandwiched therebetween.

[0252] The first panel is more stretchable than the second panel.

[0253] One of the first panel and the second panel has a higher melting point than the other of the first panel and the second panel.

[0254] According to another aspect, the present disclosure provides a rear portion of headgear, the rear portion including first and second overlapped panels defining an overlap region where the first and second panels overlap above and below one another, respectively, and a non-overlapping region where the first panel is not overlapped, and in the overlap region adjacent surfaces of each overlapped panel are fused together.

[0255] The lateral ends of the overlap region are left unfused to receive headgear straps between the first and second panels.

[0256] According to another aspect, the present disclosure provides headgear including a rear portion and a pair of straps, each strap sandwiched between a first panel and a second panel at a lateral end of the overlap region.

[0257] The overlapping first panel, second panel and strap are fused to one another at each lateral end of the overlap region.

[0258] According to another aspect, the present disclosure provides headgear including a plurality of panels, at least a portion of each panel overlapping at least a portion of the other panels, which are joined together to provide a thin, seamless or substantially seamless headgear.

[0259] The overlapping portions of each panel are joined together by fusing one or both panels to the other or each other of the panels.

[0260] According to another aspect, the present disclosure provides headgear including a plurality of panels, at least a portion of each panel overlapping at least a portion of the other panels, which are fused together to provide lightweight headgear.

[0261] According to another aspect, the present disclosure provides headgear including a plurality of panels, at least a portion of each panel overlapping at least a portion of the other panels and fused together, the panels being configured to retain at least a portion of their in-use shape when the headgear is at rest.

[0262] At least one of the plurality of panels includes a different material than another panel of the plurality of panels.

[0263] At least one of the panels in the overlap region includes a different material than the other panels in the overlap region.

[0264] The plurality of panels includes a first panel and a second panel, the first panel including a different material than the second panel.

[0265] The plurality of panels further includes a third panel, the second panel and the third panel including the same material that is a different material than the first panel.

[0266] The different materials include one or more of different textures, softness, stretch properties including one or more of in-plane stiffness, out-of-plane flexibility and recovery, density, thickness, color, coefficient of friction against a reference material, breathability, or transparency or see-throughness.

[0267] The different materials have one or more of directionally different texture, softness, in-plane stiffness, out-of-plane flexibility, elastic properties including one or more of recovery, or coefficient of friction relative to a reference material.

[0268] The two opposing major surfaces of at least one panel of the plurality of panels include one or more of a different texture, coefficient of friction, or color of the opposing major surfaces of the panels.

[0269] The exposed portions of the major surfaces of the plurality of panels define inner and outer surfaces of the headgear relative to a patient's head in use, with at least some of the plurality of panels defining portions of the inner and / or outer surfaces of the headgear, respectively.

[0270] At least some of the plurality of panels include one or more of a different texture, softness, color, or coefficient of friction relative to a reference material.

[0271] At least a portion of the panels defining a portion of the inner surface of the headgear includes a surface softness that is greater than at least a portion of the panels defining a portion of the outer surface of the headgear.

[0272] Only a portion of the plurality of panels defines an inner surface and only a portion of the plurality of panels defines an outer surface.

[0273] Except for the or each at least one non-overlapping configuration, the exposed portion of the panel defines a portion of one or the other of the inner and outer surfaces.

[0274] The plurality of panels includes a panel of a first stretchable material and a panel of a second stretchable material, the first stretchable material and the second stretchable material having different stretch properties.

[0275] The first elastic material is more elastic than the second elastic material.

[0276] The plurality of panels includes at least one elastic fabric panel and at least one non-elastic fabric panel.

[0277] The panels include: a rear portion for positioning behind the patient's head; Top strap, and At least two side straps for attachment to the patient interface.

[0278] The rearward portion transfers loads between the at least two side straps, and the rearward portion includes at least one panel of a first material overlapping a portion of a side strap panel of each of the at least two side straps.

[0279] The rear portion includes a plurality of panels of a first material, and each of the at least two side straps is overlapped on each side by a panel of the first material.

[0280] The area of ​​the rear portion which is positioned lowest at the rear of the user's head includes a lower panel of the second material.

[0281] The second material is a non-disentangleable material.

[0282] The bottom panel overlaps or is disposed between one or more of the multiple panels of the first material.

[0283] The bottom panel of the second material is more stretchable than the panels of the first material.

[0284] The bottom panel of the first material is a stretchable panel and the panels of the first material are non-stretchable panels.

[0285] The bottom panel of the second material is elastic and the panels of the first material are inelastic.

[0286] The bottom panel of the second material has a higher elasticity than the panels of the first material.

[0287] The second material is an elastic material and the first material is a substantially inelastic material.

[0288] A portion of the lower panel is in a non-overlapping region of the headgear, and a portion of the lower panel is substantially crescent-shaped.

[0289] At least a portion of the lower panel in the non-overlapping region of the headgear is substantially crescent-shaped and has a concave edge and a convex edge, the concave edge forming at least a portion of the lower periphery of the rear portion.

[0290] The rear portion includes a top edge panel that forms at least a portion of an upper periphery of the rear portion, the top edge panel comprising a material that is thinner and / or softer than the material of the panel it overlies.

[0291] The upper edge panel overlaps another panel of the rear portion to define an inner surface against the patient's head during use of the headgear at an upper region of the rear portion.

[0292] An upper border panel is provided in both the overlap region and the non-overlapping region, the non-overlapping region forming at least a portion of the upper periphery of the rear portion.

[0293] The top edge panel in the non-overlapping region is configured to roll away from the patient's head in use and towards the upper periphery of the rear portion.

[0294] The top panel in the non-overlapping region extends away from the adjacent overlapping region a distance between about 5 times and about 20 times the thickness of the top panel.

[0295] The upper strap defines an inner surface that faces towards the patient's head in use and an outer surface that faces away from the patient's head in use, the inner surface having a greater softness than the outer surface.

[0296] An upper strap depends from the rear portion.

[0297] The top strap depends from the rear portion and from at least one side strap on each lateral side of the rear portion and / or the top strap.

[0298] The top strap has a width greater than the width of at least two of the side straps.

[0299] The top strap is a different color than at least two of the side straps.

[0300] The top strap includes a pair of top strap portions adjustably securable to one another to provide a top strap of variable length, with each top strap portion including an inner top strap portion panel and an outer top strap portion panel adhesively bonded to one another.

[0301] The inner upper strap portion panel has a greater softness than the outer upper strap portion panel.

[0302] The inner and outer upper strap portion panels overlie and underlie, respectively, the panel or panels of the rear portion and / or side strap over which they overlap.

[0303] The upper straps are relatively stiffer and / or denser than the rear portion.

[0304] The upper strap includes one or more panels of material having a higher stiffness and / or higher density than the panel or panels making up the rear portion.

[0305] The at least two side straps include two lateral sets of upper and lower side straps, each set of side straps for connection to a corresponding side of the patient interface.

[0306] The two upper side straps include an integral panel that extends across the rear portion of the headgear.

[0307] Integral panels are provided within the overlapping region over at least a portion of the rear portion of the headgear and within a pair of distal non-overlapping regions.

[0308] The upper and lower straps include integral panels that are configured to extend around the backs of the patient's ears.

[0309] The overlap regions of the upper side straps are overlapped above and below, respectively, by panels of the upper strap.

[0310] The lower side straps are overlapped and underlain by multiple panels in the rear portion.

[0311] Ear loops for passing behind the patient's ears define the lateral periphery of the rear portion between each lateral set of upper and lower side straps.

[0312] The edge profile of each ear loop includes a pair of straight line segments.

[0313] The pair of straight sections form a V-shape with the tip of each V pointed toward the other and entering the rear portion of the headgear.

[0314] The two upper side straps include two respective panels, one each provided within the overlap region and the distal non-overlapping region at the rear portion of the headgear.

[0315] Each of the two respective panels of the two upper side straps is overlapped above and below by a panel of the rear portion of the headgear.

[0316] The end portions of either or both of the upper and lower side straps include gripping tabs that include first and second tab panels that overlie and underlie the end portions at a first tab region, respectively, and overlie each other at a more distal second tab region.

[0317] The first and second tab panels are of a material that is one or more of thinner, softer, a different color, or has a lower coefficient of friction relative to a reference material than the material of each strap of the set of upper and lower side straps.

[0318] The first and second tab panels are a plastic material that is one or more of thinner, harder, stiffer, a different color, or has a lower coefficient of friction relative to a reference material than the material of each strap of the set of upper and lower side straps.

[0319] The headgear in the second, more distal tab region is of greater stiffness than the headgear in the first tab region.

[0320] The second, more distal tab region is thinner than one or more of the upper and lower side straps in the non-overlapping regions.

[0321] The grip tab further includes a first half of a hook and loop fastener on one outer surface.

[0322] The side strap is configured such that a surface of the strap corresponding to a first half of the hook and loop fastener includes a second half of the hook and loop fastener when the strap is folded back on itself.

[0323] The at least two side straps include a left side strap and a right side strap, each side strap for connecting to a corresponding side of the patient interface.

[0324] Each side strap of the set of side straps is adapted to be folded back upon itself and attached to define a connecting loop capable of holding a patient interface.

[0325] Each side strap of the set of side straps includes a series of visual features along at least one surface of the side strap, the visual features being for indicating adjustment points to the patient when folding the side strap back on itself.

[0326] The visual features are regularly spaced along a surface of each side strap.

[0327] Each side strap of the set of side straps includes a series of tactile features along at least one surface of the side strap, the tactile features for providing tactile feedback to the patient of different adjustment states of the respective strap.

[0328] A series of tactile features provide indication of the adjustment of each respective side strap.

[0329] Interaction of the patient interface with the haptic features provides tactile feedback to the patient.

[0330] Each side strap includes a strap panel that is overlaid on at least one major surface with a tactile feedback panel that is one or more of thinner, harder, and stiffer than the strap panel it overlies, and the tactile feedback panel and the strap panel are fused together.

[0331] The tactile feedback panel includes tactile features provided by a series of voids extending through the tactile feedback panel.

[0332] The series of voids present the tactile feedback panel as having a series of ridges relative to the strap panel over which it is overlaid.

[0333] The tactile feedback panel is stiffer and / or more rigid than the strap panel and has a series of ridges for mechanically engaging with a buckle on the patient interface.

[0334] The lateral extents of each of the top strap and rear portion interface with each other and with an end of each one of the side straps without overlap.

[0335] The lateral extents of each of the top straps and rear portion and the ends of each of the side straps interface with one another in an edge-to-edge configuration.

[0336] The lateral extent of each of the top straps and rear portion and the ends of each of the side straps are overlapped on at least one set of major faces by joining panels.

[0337] At least one major surface of one or more of the top strap, rear portion and side straps are overlapped along at least a portion towards their periphery by the reinforcing panel.

[0338] The reinforcing panel comprises a stretchable material that is less stretchable than one or more of each of the top straps, the rear portion and the side straps.

[0339] The reinforcing panel comprises a relatively low stretch material.

[0340] The reinforcing panel comprises a reduced stretch material.

[0341] The reinforcing panel comprises a non-stretchable material.

[0342] The reinforcing panel comprises a substantially non-expandable material.

[0343] The reinforcing panel comprises a non-elastic material.

[0344] The upper strap comprises a single, one-piece strap.

[0345] The rear portion includes a single integral strap.

[0346] The top strap and the rear portion include closed loops.

[0347] A set of side straps depend from the intersection of the top straps and the rear portion.

[0348] The intersection of the upper strap and rear portion rests over the patient's ear in use.

[0349] One or more of the set of side straps, the rear portion and the top strap include a first stretch panel that is at least partially overlapped by a pair of second stretch panels, the first stretch panel being more stretchable than the second stretch panels.

[0350] One or more of the set of side straps, the rear portion and the top strap at least partially include a relatively elastic panel overlapped by a respective relatively inelastic panel.

[0351] The entirety of one or both of the top straps and the rear portion includes a first stretch panel overlaid by a pair of second stretch panels, the first stretch panel being more stretchable than the second stretch panels.

[0352] The entirety of either or both of the top straps and rear portion includes relatively elastic panels overlapped above and below by respective relatively inelastic panels.

[0353] The rear portion and the top strap form a closed loop, with the rear portion and the top strap together including relatively higher stretch panels and relatively lower stretch panels.

[0354] The rear portion and upper strap include two relatively lower stretch panels, each overlapped with a relatively higher stretch panel at a respective first end and overlapped with each other at an opposite end.

[0355] The rear and crown portions include a single relatively low stretch panel that is overlapped at two lateral ends by one or more relatively high stretch panels.

[0356] The terminal portions of either or both of the upper and lower side straps include gripping tabs that include first and second tab panels that overlie and underlie the terminal portions, respectively, at a first tab region and overlie each other at a more distal second tab region.

[0357] The first and second tab panels are of a material that is one or more of thinner, softer, a different color, or has a lower coefficient of friction than the material of each strap of the set of upper and lower side straps.

[0358] The headgear in the second, more distal tab region is of greater stiffness than the headgear in the first tab region.

[0359] The grip tab further includes a first half of a hook and loop fastener on one outer surface.

[0360] The side strap is configured such that a surface of the strap corresponding to a first half of the hook and loop fastener includes a second half of the hook and loop fastener when the strap is folded back on itself.

[0361] One or more of the plurality of panels comprises a releasable material.

[0362] At least a portion of the edges of the headgear are treated with a conditioner.

[0363] Edges treated with the conditioner contain increased fray resistance compared to unbonded overlapped edges of the same material.

[0364] At least a portion of the edge of the headgear is rolled back onto itself.

[0365] An adhesive is provided between the unwound portion and the portion it is being unwound from.

[0366] At least a portion of the edge of the headgear includes an edge softening panel, a portion of the edge softening panel overlapping an inner panel, the edge panel including a thinner and / or softer material than the material of the inner panel over which it overlaps.

[0367] The edge panels overlap the more inner panels so that the edge panels define an inner surface of the headgear against the patient's head in use.

[0368] The edge panel is configured to roll towards its outer end, away from the patient's head, during use.

[0369] An edge panel in a non-overlapping region extends away from the adjacent overlapping region a distance from about 5 to about 20 times the thickness of the inner panel it overlaps.

[0370] The headgear has a weight of less than about 30 g.

[0371] The headgear has a weight of less than about 20 g.

[0372] The headgear has a weight of less than about 10 g.

[0373] The headgear has a weight of about 15 g to about 30 g.

[0374] The headgear has a weight of about 17.5 to about 27.5 g.

[0375] The headgear has a weight of approximately 25 g.

[0376] One or more of the plurality of panels includes a planar panel.

[0377] One or more of the plurality of panels includes a tubular panel.

[0378] According to another aspect, the present disclosure provides headgear including a first panel including a selectively fused zone, where in the selectively fused zone, the first panel is continuously fused along a first direction and at least partially discontinuously fused along a second direction, the second direction being a different direction than the first direction.

[0379] Within the selectively fused zone and in the first direction, all of the fused portions of the first panel are contiguous with one another.

[0380] Within the selectively melted zone and in the second direction, at least some of the melted portions of the first panel are discontinuous with one another.

[0381] Within the selectively fused zones and in the second direction, the fused regions are discontinuous.

[0382] The headgear includes a first panel and an at least partially overlapped second panel, and the selectively fused zone includes at least a portion of the overlapped panels.

[0383] In the selectively fused zones, the headgear is less stretchable in a first direction relative to a second direction.

[0384] The second direction is substantially perpendicular to the first direction.

[0385] The selectively fused zones are provided in one or more elongated portions of the headgear, with a first direction taken transverse to the length of each elongated portion and a second direction taken along the length of each elongated portion.

[0386] The elongated portion includes a plurality of straps.

[0387] The elongated portion includes a rear loop.

[0388] The selectively fused zone is disposed at a bifurcated portion of the headgear, the second direction being across the bifurcated portion and the first direction being along each side of the bifurcated portion.

[0389] The first direction is a direction of load transfer between the two portions of the headgear, and the second direction is substantially perpendicular to the load transfer direction.

[0390] The headgear includes a first selectively fused zone between the lateral sides of a rear portion of the headgear and second and third selectively fused zones between respective lower strap connection portions of the rear portion and the first selectively fused zone.

[0391] The selectively fused zones are configured such that, when coupled to the interface, the headgear defines a continuous loop of fused material from the first side of the interface around the patient's head to the second side of the interface.

[0392] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including first and second overlapping panels defining an overlapping region where the first and second panels overlap above and below, respectively, and a non-overlapping region where the first panel is not overlapped, the panels being fused to one another at the overlapping region, and the non-overlapping region varying in width.

[0393] The non-overlapping areas are relatively more stretchable than the overlapping areas.

[0394] The first panel is a stretch panel and the second panel is a non-stretch or relatively low stretch panel.

[0395] The headgear includes one or more elastic zones in which the or each elastic zone provides a localized increase in width of the non-overlapping region.

[0396] The non-overlapping regions have a locally increased width at the ear loops of the headgear which are placed around the patient's ears in use.

[0397] The maximum width of the non-overlapping area of ​​the headgear ear loops is the area that is located above and behind the patient's ears when in use.

[0398] In the ear loops, the ratio of the total width of the non-overlapping region(s) to the overlapping region is from about 1:1 to about 3:1.

[0399] The non-overlapping area at the upper side of the rear portion of the headgear has a substantially constant width, and the non-overlapping area at the lower side of the rear portion of the headgear varies in width.

[0400] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including first and second overlapping panels defining an overlap region where the first and second panels overlap above and below each other, respectively, a filament is provided between the first and second panels in the overlap region, and the panels are fused to each other on either side of the filament.

[0401] The filament can be drawn between the panels.

[0402] The filament extends around a loop of the headgear between the two patient interface connection ends of the headgear, and the filament is retractable between the panels to adjust the fit of the headgear.

[0403] According to another aspect, the present disclosure provides a headgear for a patient interface, the headgear comprising three reinforcing structures on each side of the headgear: a) a first reinforcing structure that provides stiffness between a rear portion of the headgear and an upper strap; b) a second reinforcing structure that provides stiffness between the top strap and the top side strap of the headgear; c) A third reinforcing structure that provides stiffness between the rear portion of the headgear and the lower side straps. and the three reinforcing structures are formed by fusing the headgear at their respective locations.

[0404] The headgear includes a first panel, and the fusing of the headgear includes fusing the first panel.

[0405] The headgear further includes a second panel at least partially overlapped with the first panel, and the fusing includes at least partially fusing the overlapping first and second panels.

[0406] The panel or panels include a fabric that includes a polymeric material, and when the panel or panels are fused together, they form a solid plastic.

[0407] The three reinforcing structures are formed by fusion bonding of one or more panels, with the elimination of additional components provided to the panel or panels.

[0408] The three reinforcing structures are continuous with each other.

[0409] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including a rear portion having first and second overlapping panels and at least two straps, each of the at least two straps fused to only a first panel of the rear portion.

[0410] The second panel does not overlap any of the at least two straps.

[0411] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear including a rear portion having first and second overlapped panels and a plurality of straps overlapped and fused to the rear portion, each portion of the straps not overlapped to the rear portion being straight.

[0412] The unoverlapped rear portion of each strap is of constant width.

[0413] Both the portion of each strap that overlaps the rear portion and the portion that does not overlap are straight and / or of constant width.

[0414] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; at least one slot cut in the second panel; at least one strap, each strap having a strap end inserted into a respective slot so as to be positioned between the stacked first and second panels; wherein each of the at least one strap and the rear portion are joined by fusing the first and second panels and each of the at least one strap ends.

[0415] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; at least one slot cut in the second panel; at least one strap, each strap being inserted through a respective slot and having a strap end folded back on itself; Includes.

[0416] Each of the at least one straps is joined to the rear portion by being fused to itself at the folded-back portion.

[0417] Each of the at least one straps is joined to the rear portion by releasably connecting the strap to itself at the folded-back portion.

[0418] At least one slot is cut through both the first panel and the second panel.

[0419] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; an upper strap having a thinned central region sandwiched between the first and second overlapping panels of the rear portion; wherein the rear portion and the upper strap are joined by fusion bonding.

[0420] Prior to being assembled into the headgear, the upper strap has a straight shape.

[0421] The upper strap when sandwiched between the first panel and the second panel has a curved shape.

[0422] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; Multiple straps and a strap material layer overlaid on the overlapping first and second panels, the strap material layer comprising the same material as each of the plurality of straps, each of the plurality of straps being overlaid on and fused to the strap material layer; Includes.

[0423] The headgear includes a plurality of layers of strap material, each of which is overlapped with the overlapping first and second panels, with at least one strap overlapping and fused thereto.

[0424] One or more layers of strap material are overlapped against the second panel only in the rear portion.

[0425] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; an upper strap panel partially overlapping the rear portion, the upper strap panel including a slot; A strap that extends through the slot and fastens back on itself Includes.

[0426] The headgear has left and right upper strap panels, each partially overlapping a respective left and right side of the rear portion, and each upper strap panel including a slot through which a respective strap extends and is secured back onto itself.

[0427] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels; Two straps and two overmolded parts, each overmolded onto a respective one of the two straps and securing the rear portion and the straps together; Includes.

[0428] The rear portion includes two slots extending therethrough, and the overmolded component further includes mounting posts each having a base and a head, the head of each mounting post being inserted through the respective slot to connect the rear portion and the overmolded component together.

[0429] Each head includes lateral wings that are wider than each slot.

[0430] The headgear includes four straps, two straps being overmolded by each of the overmolded parts.

[0431] The rear portion includes two slots therethrough, and the respective portions of the overmolded component are fused together through the respective slots.

[0432] According to another aspect, the present disclosure provides headgear for a patient interface, the headgear comprising: a rear portion having first and second overlapping panels and defining a strap connection area; Straps placed in the strap connection area and and wherein the rear portion is folded over the strap at the strap connection area.

[0433] The strap is joined to the rear portion by fusing the rear portion to both sides of the strap.

[0434] According to another aspect, the present disclosure provides a rear portion of headgear for or for connection to a patient interface, the rear portion including first and second overlapped panels defining an overlap region, the entire periphery of the overlap region of the first and second overlapped panels being fused to one another except for one or more strap connection regions.

[0435] The headgear is formed by interposing a portion of a strap between first and second overlapping panels at each strap connection region and fusing the panels and straps together.

[0436] The first and second panels are fused together around the entire periphery of the overlap region of the headgear.

[0437] According to another aspect, the present disclosure provides a rear portion of headgear for or for connection to a patient interface, the rear portion including first and second overlapping panels defining an overlap region, the entire periphery of the overlapping portions of the first and second panels being fused to one another except for one or more strap connection regions.

[0438] The headgear is formed by interposing a portion of a strap between first and second overlapping panels at each strap connection region and fusing the panels and straps together.

[0439] The first and second overlapped panels around the entire perimeter of the overlap region are fused to one another.

[0440] The first and second panels in the overlap region of the headgear are generally fused to one another.

[0441] According to another aspect, the present disclosure provides headgear including first and second overlapped panels, the overlapped panels defining an overlap region where the first and second panels overlap each other above and below, respectively, and the overlapped panels are fused to each other such that a straight line condition between two edges of the overlap region is satisfied, where the straight line condition provides that a total length along a line between two selected edges of the fused overlap region exceeds a total length between two non-fused edges.

[0442] The straight line condition is satisfied between at least one pair of respective upper and lower edges of the overlap region of the rear portion of the headgear.

[0443] The straight line condition is satisfied along any straight line between the upper and lower edges of the overlap region of the rear portion of the headgear.

[0444] The straight line condition is satisfied along any straight line between the two edges of the overlap area of ​​the rear portion of the headgear.

[0445] The headgear further defines a non-overlapping area where the first panel is not overlapped.

[0446] Along a line between the edges of the overlap region, fused portions are located at opposite ends of the line.

[0447] Along the line between the edges of the overlap region, the unfused portions are located only away from either end of the line.

[0448] Along a line between the edges of the overlap region, the cumulative length along the line at that end where the overlap portion is fused exceeds the cumulative length along the line where the overlap portion is not fused.

[0449] Along a line between the edges of the overlap region, the cumulative length along the line at the ends where the overlap portions are fused exceeds the cumulative length along the line in the central portion where the overlap portions are not fused.

[0450] While the headgear will generally be referred to in relation to a patient, it will be understood that the term patient may be substituted, where appropriate, for the patient's assistant or medical professional or anyone else who may use or interact with the headgear, whether in relation to their own use or assisting someone else in using the headgear.

[0451] As used herein, the term "and / or" means "and" or "or" or both.

[0452] As used herein, "(s)" following a noun refers to the plural and / or singular form of that noun.

[0453] For the purposes of this specification, the term "plastic" shall be taken to mean a general term for a wide variety of synthetic or semi-synthetic polymerization products, generally consisting of hydrocarbon-based polymers.

[0454] For purposes of this specification, when method steps are described in a sequence, the sequence does not necessarily imply that the steps are chronologically arranged in that order, unless there is another logical way to interpret the sequence.

[0455] As used in this specification and the claims, the term "comprises" means "consisting at least in part of." When interpreting each description containing the term "comprises" in this specification, there may be other features present than those prefaced by the term. The related terms "comprise" and "comprises" are to be interpreted in the same manner.

[0456] Other aspects of the invention may become apparent from the following description, given by way of example only and with reference to the accompanying drawings, in which:

[0457] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the drawings, in which: [Brief description of the drawings]

[0458] [Figure 1A] FIG. 2 is a cross-sectional view of the configuration of the two panels before they are fused together. [Figure 1B] FIG. 2 is a cross-sectional view of the configuration after fusing the two panels. [Figure 2A] FIG. 2 is a cross-sectional view of another pre-fusion configuration of two panels. [Figure 2B] FIG. 13 is a cross-sectional view of another post-fusion configuration of two panels. [Figure 3A] FIG. 2 is a cross-sectional view of another pre-fusion configuration of two panels. [Figure 3B] FIG. 13 is a cross-sectional view of another post-fusion configuration of two panels. [Figure 4A] FIG. 2 is a cross-sectional view of the configuration of the three panels before fusion. [Figure 4B] FIG. 2 is a cross-sectional view of the configuration after fusing of the three panels. [Figure 5A] FIG. 2 is a cross-sectional view of the two panels before they are fused together. [Figure 5B] FIG. 2 is a cross-sectional view of the two panels after fusing. [Figure 6A] FIG. 2 is a cross-sectional view of the configuration of the three panels before fusion. [Figure 6B] 6B shows the configuration after fusing of the three panels of FIG. 6A. [Figure 6C] 6B shows the configuration after fusing of the three panels of FIG. 6A. [Figure 7A] FIG. 2 is a plan view of two panels stacked on top of each other. [Figure 7B] 7B shows the area around the periphery of the overlap of the two panels of FIG. 7A where the two panels are joined together. [Figure 7C] 7B, but with the panels and bond areas misaligned relative to one another. [Figure 8A] FIG. 2 is a plan view of two panels stacked on top of each other. [Figure 8B] 7B shows the area across the overlap of the two panels of FIG. 7A where the two panels are joined together. [Figure 8C] 7B, but with the panels and bond areas misaligned relative to one another. [Figure 9A] FIG. 1 is a side view of a welding press for welding headgear, the welding press being open. [Figure 9B] FIG. 2 is a side view of a welding press for welding headgear, the welding press being closed. [Figure 10] FIG. 1 is a diagram of the headgear holding the interface against the patient's face. [Figure 11] FIG. 2 is a plan view of the headgear. [Figure 12] Two panel diagram. [Figure 13] FIG. 13 is a diagram of the two panels of FIG. 12 superimposed on one another to define a portion of headgear. [Figure 14]FIG. 14 is a diagram of the headgear of FIG. 13 with the panels fused together. [Figure 15] FIG. 1 is a diagram of headgear showing boundaries where fusion can be applied to panels of the headgear. [Figure 16] FIG. 15 is a close-up view of a portion of the headgear of FIG. 14 showing the two overlapping panels and the boundary where the fusion is applied. [Figure 17A] FIG. 2 is a plan view of the headgear. [Figure 17B] FIG. 17B is a plan view of the headgear of FIG. 17A with the straps joined. [Figure 18] FIG. 2 is a plan view of the headgear. [Figure 18-1] FIG. 2 is a plan view of the headgear. [Figure 18-2] FIG. 18-2 is a diagram of the headgear of FIG. 18-1 worn by a patient. [Figure 18-3] FIG. 1 shows four different rear sections of the headgear. [Figure 19] FIG. 2 is a plan view of the headgear. [Figure 20] FIG. 20 is a diagram of a die for forming the headgear of FIG. [Figure 21] FIG. 2 is a plan view of the headgear. [Figure 22] FIG. 22 is a diagram of a die for forming the headgear of FIG. 21. [Figure 23] FIG. 2 is a plan view of the headgear. [Figure 24] FIG. 24 is a diagram of a die for forming the headgear of FIG. 23. [Diagram 25] FIG. 13 is a diagram of another configuration of a die having indicia forming elements. [Figure 26] FIG. 13 is a view of a portion of headgear having indicia formed thereon. [Figure 26-1A] FIG. 1 is a diagram of the headgear and patient interface. [Figure 26-1B] A cross-sectional view taken along line AA in Figure 26-1A. [Figure 27] FIG. 2 is a plan view of headgear with indicia formed thereon. [Figure 28A] FIG. 2 is a plan view of the headgear before fusing. [Figure 28B]FIG. 28B is a view of the headgear of FIG. 28A after fusing. [Figure 29] FIG. 2 is a plan view of the headgear. [Diagram 30] FIG. 2 is a plan view of the headgear. [Diagram 31] FIG. 2 is a plan view of the headgear. [Diagram 32] FIG. 2 is a plan view of the headgear. [Diagram 33] FIG. 2 is a plan view of the headgear. [Diagram 34] FIG. 2 is a plan view of the headgear. [Diagram 35] FIG. 13 illustrates the hanging configuration of the headgear when held by the patient. [Figure 36A] FIG. 2 is a diagram of headgear on a patient's head. [Figure 36B] FIG. 2 is a diagram of headgear on a patient's head. [Figure 37A] A panel for part of the strap. [Figure 37B] 37B shows the panel of FIG. 37A joined to another strap panel. [Figure 38] 1 shows an alternative strap panel. [Figure 39A] FIG. 13 is a top view of a strap end feature. [Figure 39B] FIG. 13 is a side view of a strap end feature. [Figure 40A] FIG. 2 is a plan view of headgear with punched out portions. [Figure 40B] FIG. 2 is a plan view of headgear with punched out portions. [Figure 40C] FIG. 13 is a view of the rear portion of the headgear with the cut-out portion. [Diagram 41] 1A-1C are partial views of two configurations of headgear. [Diagram 42] FIG. 1 is a diagram of a continuous fusion process for forming a portion of headgear. [Diagram 43] FIG. 13 is an illustration of another continuous fusion process for forming a portion of headgear. [Diagram 44]FIG. 13 is an illustration of another continuous fusion process for forming a portion of headgear. [Diagram 45] FIG. 13 is a diagram of another continuous welding process for forming a portion of headgear, the portion of headgear being stretched prior to welding. [Figure 46-1A] FIG. 1 shows a panel of headgear and two inserts. [Figure 46-1B] FIG. 2 is a diagram of two fused panels with a pocket formed between them. [Figure 46-2] FIG. 1 is a diagram of two fused panels with an air gap formed between them. [Figure 46-3] FIG. 2 is a diagram of two fused panels with a continuous pocket formed therebetween. [Figure 47A] FIG. 13 is a diagram of the headgear and interface in which fused headgear panels define air conduits. [Figure 47B] FIG. 47B is a cross-sectional view of the air conduit through line AA of FIG. 47A. [Figure 48A] 11A-11D are diagrams of steps in the process of joining the straps to another portion of the headgear. [Figure 48B] 11A-11D are diagrams of steps in the process of joining the straps to another portion of the headgear. [Figure 48C] 11A-11D are diagrams of steps in the process of joining the straps to another portion of the headgear. [Figure 48D] 11A-11D are diagrams of steps in the process of joining the straps to another portion of the headgear. [Figure 49A] FIG. [Figure 49B] FIG. 49B is a diagram of an illustrated fusing pattern that can be applied to the panel of FIG. 49A. [Figure 49C] FIG. 49B is a diagram of an illustrated fusing pattern that can be applied to the panel of FIG. 49A. [Figure 49D] FIG. 49B is a diagram of an illustrated fusing pattern that can be applied to the panel of FIG. 49A. [Figure 50] FIG. 1 is a diagram of a portion of the headgear. [Figure 51] FIG. 1 is a diagram of a portion of the headgear. [Figure 52] FIG. 2 is a view of the rear portion of the headgear. [Figure 53] FIG. 13 is a view of another rear portion of the headgear. [Figure 54] FIG. 2 is a view of the rear portion of the headgear when the headgear is worn by a patient. [Figure 55A] FIG. 2 is a diagram of a fusion arrangement provided on a panel. [Figure 55B] Illustrates the performance of fused panels under load conditions. [Figure 55C] Illustrates the performance of fused panels under load conditions. [Figure 56A] FIG. 1 shows a pre-stretched and fused panel. [Figure 56B] FIG. 56B is a view of the fused panel of FIG. 56A when pre-stretching is released. [Figure 57] FIG. 1 is a diagram of the headgear and interface as worn by a patient. [Figure 58] FIG. 1 is a diagram of the headgear and interface as worn by a patient. [Figure 59] FIG. 1 is a diagram of the headgear and interface. [Figure 60A] FIG. 13 is a diagram of a headgear and interface with integral adjustment fasteners for the headgear straps. [Figure 60B] FIG. 60B is a partial cross-sectional view taken along line AA of FIG. 60A. [Figure 61A] FIG. 13 illustrates a strap with an integrated fastener. [Figure 61B] FIG. 61B is a view of the fasteners and panels that form the strap of FIG. 61A before the components are joined. [Figure 62] FIG. [Figure 63] FIG. 1 is a diagram of two overlapping panels configured to provide a smooth edge. [Figure 64] FIG. 13 is another view of two overlapping panels configured to provide a smooth edge. [Figure 65] FIG. 1 is a diagram of two overlapping panels configured to provide smooth edges on both sides of the panels. [Figure 66] FIG. 1 is a diagram of two overlapping panels configured to provide smooth edges on both sides of the panels. [Figure 67] FIG. 1 is a diagram of two overlapping panels configured to provide smooth edges on both sides of the panels. [Figure 68A] FIG. 1 is a diagram of the headgear and interface. [Figure 68B] FIG. 68B is a cross-sectional view taken along line AA of FIG. 68A. [Figure 69A] 1A-1D are diagrams of a process for forming slider features. [Figure 69B] 1A-1D are diagrams of a process for forming slider features. [Figure 69C] FIG. 69C is a diagram of a panel having the slider feature of FIG. 69B with another panel folded around its edge to make the edge smooth. [Figure 70A] FIG. 13 is a diagram of a panel having fused control features formed thereon. [Figure 70B] FIG. 70B is a cross-sectional view taken along the length of the panel of FIG. 70A. [Figure 71] FIG. 13 is a diagram of a panel having fused control features formed thereon. [Figure 72A] FIG. 1 is a diagram of the headgear and interface. [Fig. 72B] FIG. 72B is a cross-sectional view taken along line AA of FIG. 72A. [Fig. 72C] FIG. 2 is a diagram illustrating a continuous process for forming a headgear portion having filaments therein. [Fig. 72D] FIG. 1 is a diagram of two fused panels with a filament capable of sliding between them. [Figure 73] FIG. 13 is a diagram of headgear that can be adjusted by pulling a filament located within a portion of the headgear. [Figure 74] FIG. 2 is a plan view of the headgear. [Figure 75] FIG. 2 is a plan view of the headgear. [Figure 76] FIG. 2 is a plan view of the headgear. [Figure 77A] FIG. 2 is a plan view of the headgear. [Fig. 77B] FIG. 77B is a partial view of a headgear such as the headgear of FIG. 77A, showing the connection of the straps to a rear portion of the headgear. [Figure 78] FIG. 2 is a plan view of the headgear. [Figure 79A] FIG. 2 is a plan view of the upper strap of the headgear. [Figure 79B] FIG. 79B is a plan view of headgear including the upper strap of FIG. 79A. [Figure 80] FIG. 2 is a plan view of the headgear. [Figure 81] FIG. 2 is a plan view of the headgear. [Figure 82A] FIG. 13 is a partial pre-assembled view of the two straps and rear portion of the headgear with overmolded parts. [Fig. 82B] FIG. 2 is a plan view of the headgear. [Figure 83A] FIG. 2 is a partial unassembled view of the straps and rear portion of the headgear. [Figure 83B] FIG. 83B is an assembled view of the strap and rear portion of FIG. 83A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0459] Described herein are various embodiments of headgear for respiratory interfaces. Such headgear may include a plurality of panels configured to present a headgear having at least one overlapping region where at least two of the plurality of panels overlap one another and at least one non-overlapping region where one or more of the panels are not overlapped by another panel. The panels in one or more of the overlapping regions may be joined to one another, such as by fusing.

[0460] Exemplary overlapping and non-overlapping panel configurations and details of fusing those panels will now be described with particular reference to Figures 1A-5C, which may be understood to show cross-sectional or partial cross-sectional views of headgear according to the present disclosure or of various component parts from which the headgear may be constructed.

[0461] FIG. 1A is a cross-sectional view of two stacked panels, a first panel 1 and a second panel 2.

[0462] The panels may be selected from any suitable panel-like material, including fabrics that are networks of natural and / or man-made fibers, more particularly such fabrics that may be made by weaving, knitting, spreading, crocheting, bonding or other available methods.

[0463] The panels may also include any other non-conventional fabric material that may be provided in panel form, such as plastic or composite.

[0464] An individual panel, at least in some configurations, may be a single ply or layer of one material or a single composite of multiple materials, as opposed to multiple layers of the same or different materials.

[0465] The panels may be in sheet form or may include tubular panels.

[0466] The panels may have a 2D shape. Alternatively, one or more of the panels forming the headgear may have a 3D shape.

[0467] In at least some embodiments, some or all of the panels may be of a flexible material, particularly one that may sag under its own weight, which may be particularly suitable for forming parts of headgear that are to conform to the shape of a patient's head.

[0468] Each panel of the plurality of panels making up the headgear defines two opposing major surfaces, which, in at least some embodiments, may be overlapped and joined together within one or more overlapping regions of the headgear.

[0469] The multiple panels may each be panels of the same material.

[0470] In various configurations, at least some of the panels may be of different materials.

[0471] Different panels, including those that may include different materials, may define various material properties or characteristics. Headgear formed from these panels may be defined by these material properties. When panels are processed by being fused or when overlapping panels are fused to one another, the properties of each panel and the headgear may be further altered by the fusion.

[0472] The material properties of the panels include stretch properties. The stretch properties of a panel, headgear or part of headgear primarily refer to its in-plane extensibility. A panel having a relatively greater stretch property has a relatively greater extensibility, and vice versa.

[0473] The in-plane stiffness of a panel refers to the degree to which the panel resists in-plane extension or stretching. Conversely, the flexibility of a panel refers to the out-of-plane stiffness properties of the panel, e.g., the degree to which the panel sags.

[0474] The extensibility of the panels may be omnidirectional, such that the panels or headgear have the same in-plane extensibility in all directions. The stretch properties of the panels may be directionally different, such that the panels have different extensibility or are extensible and non-extensible in different in-plane directions.

[0475] Stretchable panels may have at least some in-plane extensibility. Non-stretchable panels may be relatively inextensible in-plane in at least one direction.

[0476] The panels may have different stretch characteristics from one another, for example a first panel may have a first stretchability while a second panel has a second, different stretchability.

[0477] If the panels are overlapped but not fused to one another, they may define a different third elasticity. If the panels are overlapped and fused to one another, they may define a different fourth elasticity. Furthermore, if neither the first nor the second panel is overlapped but fused to one another, it may define a fifth elasticity different from either the first or second elasticity.

[0478] A panel that has stretch properties such that it is extensible may or may not recover some or all of the stretch when the stretch load is removed. In at least some configurations, the stretch properties of a stretch panel may include recovery, such that the panel, after being stretched, may return or return towards its original unstretched shape when the stretch load is removed.

[0479] Resilience can be achieved, for example, by making the panel elastic. An elastic panel includes at least one elastomeric, rubber, or rubberized component. For example, an elastic panel can include at least some fibers of such elastic material. Conversely, a non-elastic panel is a panel that does not include any such elastomeric, rubber, or rubberized component. An elastic panel has a higher elasticity due to at least one elastic component than a non-elastic panel of the same material but without at least one elastic component.

[0480] The characteristics of the panel may include the texture of the panel on one or both of its major faces or on one or more of the edges surrounding the two major faces.

[0481] Another characteristic of the panel may be the softness or hardness of one or both of the major faces of the panel or of one or more of the edges surrounding the two major faces of the panel.

[0482] Further properties that one or more of the panels may have include different density, surface hardness, Young's modulus, thickness, color on one or both of the major surfaces or surrounding edges, or coefficient of friction on one or both of the major surfaces against a reference material. Different material properties may also include different degrees of breathability, different degrees of hydrophobicity or water absorbency, different permeability, or different degrees of transparency or see-through.

[0483] In addition to having any of these different material properties between panels, the individual panels themselves may also have one or more of these properties that vary directionally or positionally within the panel itself. For example, as described above, the panels may have directionally different stretch properties. The panels may also have directionally different textures or softness, flexibility, or coefficients of friction.

[0484] In addition to different material properties, different ones of the panels may have different physical configurations, including both thickness and in-plane dimensions.

[0485] Another example of a fabric panel's characteristics may be whether it includes cut or uncut pile. Whether the pile is cut or uncut may provide different surface characteristics. For example, uncut pile may exhibit loops of material at the panel surface. Materials with such uncut pile may be commonly known as unbroken loop (UBL) materials.

[0486] The presence of such loops may be desirable to function as the loop portion of a hook and loop fastening system. This configuration allows for the provision of a hook and loop fastening system without the need for additional components to be attached to the panel to provide the loops. This may result in providing headgear with at least a reduced thickness.

[0487] One or more panels used in the headgear may be disentangled, that is, their constituent fibers may be disentangled.

[0488] Additionally or alternatively, one or more panels used in the headgear may not be able to unravel and may be known as a free-cut material. Such material may be cut and the constituent fibers may not unravel or at least may not tend to unravel along the cut edges. Advantageously, such material may be cut into a shape such that the cut edges of the panels form the edges of the headgear without the need for further processing.

[0489] The panels may be selected from materials or panel configurations having other material properties that may provide the desired functionality of the headgear in which the panels will be included.

[0490] In addition to the different material properties and characteristics provided by the combination of different individual panels, composite characteristics can be provided in the overlap areas where the panels overlap.

[0491] For example, the thickness of each panel forms an overlap region having a thickness equal to the sum of the thicknesses of the respective panels.

[0492] In another example, one panel in the overlap region may be stretchable in one direction and another panel in the overlap region may be stretchable in another direction that is different or potentially perpendicular to the direction of the previous panel. In particular, if the panels are only stretchable in directions perpendicular or substantially perpendicular to one another, a feature may be provided where the panels in the non-overlapping region may be stretchable in their respective directions but may be substantially non-stretchable in the overlap region.

[0493] It will be appreciated that many other such combinations of panels having one or more different material properties can be constructed to have desired properties in both the non-overlapping and overlapping regions.

[0494] In addition to the use of panels having one or more different material properties, the properties of the headgear may be determined at least in part by the differing configurations of each overlapping panel in one or more overlapping regions of the headgear.

[0495] The overlap regions of the headgear may be fully or only partially bonded, for example, the overlap regions may include both bonded regions, where adjacent panel surfaces are bonded together, and non-bonded regions, where adjacent panel surfaces are not bonded together.

[0496] Panels that are bonded together can be bonded directly to each other. A direct bond between two panels is a bond between two panels without any other material between the two panels. For example, a direct bond between two panels can eliminate an intervening adhesive or an intervening intermediate layer. A direct bond can be a bond of one or both of the materials of each panel to each other.

[0497] According to various embodiments, at least a portion of the overlapping areas of the headgear may have panels joined by fusion bonding.

[0498] FIG. 1B shows the first panel 1 and the second panel 2 of FIG. 1A joined together by being fused.

[0499] Fusing defines the melting of a panel or at least the constituent materials of a panel. In the context of fusing two panels, fusing refers to the melting of one or both of the panels to the other or to each other, respectively. Thus, two panels can be fused by a) only or mainly melting one panel to the other, or b) simultaneously melting both panels to each other.

[0500] Thus, the panels to be fused should comprise a meltable material, such as a man-made fiber, e.g., a polymer. Similarly, in the case of two panels to be fused together, at least one of the two panels should comprise a meltable material, such as a man-made fiber.

[0501] As can be seen in FIG. 1B, the overlapping regions 21 of the first panel 1 and second panel 2 of FIG. 1A are fused to one another or fused one to the other at the overlapping surface, thereby becoming integral with one another to define a fused panel 6.

[0502] In one form, the fusing of one or more panels can be additive-free, involving a process in which fusing is applied to one or more panels, without the use of an additional material, such as an adhesive, interposed between two panels to fuse them together.

[0503] Fusing may involve applying one or both of heat and pressure to one or more panels.

[0504] The fusion may generally be by welding.

[0505] Where the panels are fused together by welding, one or more of the panels is a weldable material.

[0506] The welding may include a form of plastic welding.

[0507] For example, fusion may be provided by radio frequency (RF) or radio frequency (HF) welding, where the materials being fused include bipolar materials that are heated and melted by electromagnetic excitation. Examples of materials that may be fused by radio frequency or radio frequency welding include PVC, CPVC, polyurethane, EVA, PVDC, PET, and nylon. Fusion by radio frequency or radio frequency welding may be provided to materials that at least partially include bipolar materials.

[0508] Further examples of materials that may be fused by radio frequency or high frequency welding include PETG, TPU, LDPE.

[0509] The panel or panels fused by welding, including by radio frequency or high frequency welding, may thus comprise or consist of bipolar materials weldable by these processes. Once a fusion process, such as welding by radio frequency or high frequency welding, has been applied to the panel or panels, the panel or panels may generally become consolidated or solidified, respectively.

[0510] The panel or panels may be fused to various degrees, for example, in the case of radio frequency or high frequency welding, one or more of the welding platen spacing, welding energy, and welding time may be varied to increase or decrease the degree of fusion.

[0511] A relatively low degree of fusion may result in partial or localized consolidation of the fused materials. A relatively high degree of fusion may result in more complete or total consolidation of the fused materials. Materials exposed to a sufficient degree of fusion may cause the original material, e.g., bipolar fabric, to form a solid plastic where it was fused.

[0512] When the panels are fused together by radio frequency welding, the panels particularly comprise nylon, particularly having a nylon content of about 80% or greater, The remainder of the panels may comprise spandex or other similar polyether-polyurea copolymers.

[0513] In particular, if the panels are fabrics fused by high frequency welding, the fabric should be approximately 160 g / m 2 The density may be equal to or greater than 100 nm.

[0514] Other examples of applicable welding methods for fusing the panel or panels include ultrasonic welding, vibration or friction welding, hot wedge welding, hot air welding and induction welding.

[0515] The fusion of the two panels is at least primarily a fusion of the overlapping surfaces of each panel.

[0516] Panels joined together by fusion may differ in the degree to which they are fused together, which degree of fusion may be defined by the peel force between the fused surfaces, i.e., the force required to peel two fused surfaces together given a reference peel angle.

[0517] Panels joined together by fusion may define fusion zones in which the peel force required to peel the panels is non-zero, particularly in the fusion zones where the peel force may be substantial, even such that the panels cannot be peeled without destroying the respective panels.

[0518] Panels joined by fusion bonding may further define non-fused zones where the peel force to separate the panels is zero or substantially zero.

[0519] In addition to the fused and unfused zones, fusion-joined panels may define one or more transition zones where the peel force transitions between the fused and unfused zones. The transition zones may define a peel force gradient between the fused and unfused zones.

[0520] The transition zone may be defined by the peel force across its entire area between adjacent fused zones and adjacent unmelted zones. The transition zone may additionally or alternatively be defined by a reduced density of the fused area compared to adjacent fused zones, resulting in a relatively lower average peel force required to separate the two panels than the adjacent fused zones.

[0521] One or more overlapping regions may be fully fused, such that the entire or substantially the entire overlapping surface is joined to one another. For example, the entire overlapping surface may be joined to one another, except for a few small portions, such as portions that may be used to provide a desired texture or surface finish to the headgear. The substantially entire overlapping surface may be about 90% or even about 95% of the overlapping area.

[0522] Additionally or alternatively, one or more of the overlap regions may be partially fused, defining both fused and non-fused zones within the overlap region.

[0523] In addition to or instead of being characterized as entirely or substantially entirely fused, the fused configuration of the panels of the headgear according to the present disclosure may be described by a straight line condition, where a straight line is drawn between any two edges of a portion of the headgear, such as an overlap region or a rear portion of the headgear. Along the defined straight line, the length in the fused region is greater than the length in the unfused region. In other words, along the straight line, the welded length is greater than the unwelded length.

[0524] The straight weld length that satisfies the straightness condition can be anywhere from a majority of the total straight length to the entire straight length.

[0525] The straight line condition may be satisfied between two given points, for example between an upper edge of the overlap area of ​​the rear portion of the headgear and a lower edge of the overlap area.

[0526] The straight line condition may be satisfied between more than two pairs of given points, such as between multiple respective upper and lower edges of the overlap region of the rear portion of the headgear.

[0527] The straight line condition may be satisfied along the entire width of the rear portion of the headgear between successive positions along the upper and lower edges of the overlap region of the rear portion of the headgear.

[0528] The straight line condition may be satisfied along any straight line that can be drawn between two points located on one or more edges of a given overlap region of the rear portion of the headgear.

[0529] Along a straight line that satisfies the straight line condition, the fused and unfused lengths may be arranged in a particular manner. For example, overlapping panels may be fused at the ends of the line adjacent their respective edges. In this configuration, any unfused portions along the line are located along one or more central portions of the line, away from either end of the line.

[0530] In some configurations along a line that satisfy the straightness condition, the unfused portions along the line are located only away from either end of the line.

[0531] If a line between two edges of an overlap meets the straight-line test and fused portions are located at opposite ends of the line, the cumulative length along the line of the fused ends of the overlap may be greater than the cumulative length of all central unfused portions along the line.

[0532] Although generally described with respect to a rear portion of the headgear, other portions of the headgear, such as one or more straps of the headgear, may also satisfy the straightness condition at one or more locations along its length or along its entire length.

[0533] Fusing a panel or panels may change one or more properties of the panel or panels.

[0534] For example, melting and resolidifying the material of a panel may cause the panel to be one or more of thinner, denser, stiffer, less able to stretch, less able to recover, or have greater yield strength in stretch. Thus, in addition to bonding the panels together, selectively fusing the headgear at different overlap and non-overlapping regions may allow for control of the performance of the headgear.

[0535] For example, fusion of certain portions of the headgear may be used to create load transfer paths between different portions of the headgear.

[0536] Conversely, unfused portions of the headgear may be arranged to define stretch zones or areas of relatively greater thickness or flexibility.

[0537] Fusing one or more panels may also change one or more surface properties of the panels. For example, if the panel is a non-broken loop material at the surface, melting and resolidifying the panel or its constituent materials may reduce the number of non-broken loops presented at the surface of the panel. This may reduce the effectiveness of the panel in bonding with the hooks of a hook-and-loop fastener. It may even act to prevent the hooks of the hook-and-loop fastener system from being able to bond with the panel.

[0538] Thus, by selectively fusing and unfusing portions of a panel, the same panel or panels may result in some portions having unbroken loop surfaces and other portions not.

[0539] In addition to providing desired headgear performance, selective fusing (both the portion of one or more panels that are fused, the degree to which they are fused, and the shape or direction of the fused portions of the panels) can be utilized to provide different properties to the panels to change the "feel" or appearance of the headgear. This can be employed to provide cues to the patient or other user regarding the orientation or use of the headgear.

[0540] FIG. 2A shows a first panel 1 and a second panel 2 overlapping one another to define an overlap region 21 that are partially fused together.

[0541] A majority of the overlap region 21 is fused to define a fused zone 41, while the remainder of the overlap region is left unfused to define a non-fused zone 51. In the non-fused zone 51, the panels 1 and 2 are not joined to one another by being fused, and the peel force required to separate the layers in this zone is zero or substantially zero.

[0542] FIG. 2B shows the panel stack of FIG. 2A, but with a second unfused zone 52 separating the fused zone 41 of FIG. 2A into a first fused zone 41 and a second fused zone 42. FIG.

[0543] The panels may be fused and left unfused in any configuration of different regions to provide desired characteristics of the headgear.

[0544] Fusing of panels can result in thinning of the panel stack in the fusion zone, for example when one or both of the panels are fused or partially fused together by welding, which can occur especially when the fusion is performed by applying pressure to the portions of the panels that are fused.

[0545] 3A shows a buildup of a first panel 1 and a second panel 2 that are partially fused to define an unfused zone 51 and a fused zone 41. The thickness of the buildup in the fused zone is less than the thickness of the panels in the unfused zone.

[0546] Figure 3B shows the same build as Figure 3A, but with two spaced apart fused zones 41 and 42 and two non-fused zones 51 and 52. The first non-fused zone 51 is at the edge of the panel. The second non-fused zone 52 is located between the two fused zones 41 and 42.

[0547] Figures 1-3 show configurations in which two panels are completely stacked on top of one another. The panels may be arranged in other configurations, such as where one or both panels define a non-overlapping area or where the panels butt edge-to-edge against one another. Figure 4A shows a stack of a first panel 1, a second panel 2, and a third panel 3 illustrating several such configurations.

[0548] In Figure 4A, a first panel 1 and a second panel 2 each partially overlap one another, and then a third panel 3 partially overlaps the second panel 2, such that the edges of the first panel 1 and the third panel 3 abut one another.

[0549] The arrangement of FIG. 4A defines a first non-overlapping region 31, an overlapping region 21 and a second non-overlapping region 32.

[0550] Figure 4B shows the arrangement of Figure 4A with the panels fused together. As can be seen in Figure 4B, the overlapping surfaces of the first panel 1 and the second panel 2, and the second panel 2 and the third panel 3 are fused together.

[0551] As can be seen in FIG. 4B, the butt ends of the first panel 1 and the third panel 3 are also fused together.

[0552] The properties of the headgear in either the overlapped or non-overlapping regions are also affected by whether and to what extent one or more panels are fused.

[0553] For example, melt fusing of the panels may result in one or more of localized thinning, reduced extensibility or reduced flexibility in and potentially adjacent to the fused zone.

[0554] Thus, fused zones of the headgear may be located in both non-overlapping and overlapping regions to impart desired properties to the headgear.

[0555] One or more of the panels in the non-overlapping regions of the headgear may also be fused. Instead of acting to join two panels together, the fusion in the non-overlapping regions may act to change the material properties of the panels.

[0556] FIG. 5A shows a first panel 1 and a second panel 2 partially overlapped with each other to define a first non-overlapping area 31 of the first panel, an overlapping area 21 and a second non-overlapping area 32 of the second panel.

[0557] Figure 5B shows the result of fusing applied to both overlap region 21 and to portions of both first non-overlapping region 31 and second non-overlapping region 32. In the illustration of Figure 5B, the fusing is such that it results in a thinning of the panel or panels to which it is applied.

[0558] 5B, the fusion causes the panels to have a first fused zone 41 in the first panel, a second fused zone 42 in the fused overlapping first and second panels 1 and 2, and a third fused zone 43 in the fused second panel 2. The remaining lateral portions of each of the first and second panels are not fused and define first and second unfused zones 51 and 52.

[0559] Panels may be single-lapped as seen in any of Figures 1A-4B where one panel is only overlapped above or below by one other panel. When single-lapped panels are joined together, they form a single-lap joint. Panels may also be double-lapped, so that a panel is overlapped both above and below by two other panels on each major surface of the panel. When double-lapped panels are joined together, it may be referred to as a double-lap joint.

[0560] 6A shows a stack having a first panel overlapped above and below, i.e. double-overlapped, by a second panel 2 and a third panel 3, respectively. The stack defines a first non-overlapping region 31, an overlapping region 21 where the first panel is overlapped on either side by the second panel and the third panel, and second and third non-overlapping regions 32 and 33 of the second panel 2 and the third panel 3, respectively.

[0561] Figure 6B shows a first fused configuration of the stack of Figure 6A with fused overlap region 21. The fusion of overlap region 21 joins both overlapped surfaces of first panel 1 and second panel 2 and first panel 1 and third panel 3, respectively, to one another.

[0562] As can be seen in Figure 6B, each of the non-overlapping regions 31-33 remains unfused. In non-overlapping regions 32 and 33, the second and third panels are shown to now be overlapped together by fusing the adjacent overlapping regions.

[0563] FIG. 6C shows another fusion arrangement of the stack of FIG. 6A, where fusion has been applied across the entire section to define a first fusion zone 41 in the first panel, a second fusion zone 42 in the overlap region 21, and a third fusion zone 43 in the second and third panels which are now fused together.

[0564] Compared to a single overlap joint, a double overlap joint as shown in FIG. 6B or 6C may have the advantage of reducing the likelihood of inducing twisting at the joint under lateral loading of the respective panels. Such twisting may cause the joint to twist or otherwise deform, preventing at least a portion of the headgear from lying flat. This may be undesirable in some situations, such as when the headgear is to lie flat against the patient's head, because such twisting of the headgear may result in increased pressure points against the patient's head and therefore discomfort.

[0565] Reducing or eliminating twisting at the interface between panels may increase the strength of headgear where panels are bonded or glued together. Twisting of panels at the joints may cause the panels to experience peel stresses when under tension. The joints may be relatively limited in strength under such peel stresses where the panels are pulled away from each other perpendicular to the joint surface. Reducing twisting may mean that the panels are not twisted and are not exposed to peel stresses, but rather are exposed primarily or exclusively to helical stresses. Some bonds, particularly fusion or weld bonds, may be able to provide greater strength under shear stresses than peel stresses. This means that reducing twisting in overlapping panels may increase the strength of the headgear.

[0566] In other configurations, for example where the load is not such that it would cause the joint to twist significantly, a single lap joint may be preferred over a double lap joint because it may provide a joint with less thickness.

[0567] The single lap joint of the arrangement of Figures 4A and 4B can also function similarly to a double lap joint in that it reduces twisting when a lateral load is applied to the first panel 1 and the third panel 3, thus potentially increasing the strength of the joint.

[0568] Although various exemplary stacks of different panels and different fused and unfused configurations of such panels have been described above, it will be understood that any number of variations or combinations of such stacks and their fused configurations may be provided to form headgear.

[0569] Although shown including various panels of exemplary thicknesses, it will be understood that the above stacks may be provided with panels of different thicknesses and combinations of thicknesses, among any other desired material properties.

[0570] Unless the context indicates otherwise, the perimeter of a panel, portion, region, or of the headgear itself may be understood to generally refer to the perimeter, and more particularly the boundary within the perimeter, of the respective panel, portion, region, or headgear. If the context requires, this may alternatively be referred to as the inner perimeter.

[0571] Conversely, the outer periphery of a panel, portion, region, or of the headgear itself is generally understood to refer to the outer boundary of the periphery of the respective panel, portion, region, or headgear.

[0572] 7A-7C show plan views of two panels forming part of the headgear.

[0573] As seen in FIG. 7A, a first panel 1 is provided below a second panel 2, which is completely overlapped by the first panel. The panels define an overlapping area 21 of the same size as the second panel 2. The panels are joined together to form part of the headgear. They may be joined by fusion or, specifically, welding, as described above. They may additionally or alternatively be at least partially joined by any number of methods, such as by stitching or the use of an adhesive. For purposes of this example, the panels are joined by fusion, specifically, welding.

[0574] FIG. 7B shows a shaded boundary representing a weld 70 around the periphery of the overlap area where panels 1 and 2 of FIG. 7A are joined.

[0575] The arrangement of FIG. 7B illustrates a conventional method of joining two or more panels together, particularly by welding, where a foam layer is interposed between the two panels and it is desirable to minimize the amount of the foam layer that is welded.

[0576] However, welding the panels around the perimeter of the overlap area (70) can be difficult due to the close nature of the weld and the fine tolerances it requires. If one or both of the panels are not positioned correctly relative to the welding tool, or if the tool is positioned out of alignment relative to the panels, the weld may not finish in the desired location.

[0577] Figure 7C shows the arrangement of Figure 7B, but with the weld 70 misaligned relative to panels 1 and 2. As a result, weld 70 is partially outside the boundary of second panel 2 (at the left and top of the second panel) and only partially inside the boundary of the second panel (at the bottom and right side of the second panel). This can mean that the panels will not be properly joined together.

[0578] While Fig. 7C illustrates a misalignment between the panel and the welding tool, it will be understood that the misalignment may additionally or alternatively result from the positions of the panels relative to one another. Further, while the misalignment in Fig. 7C is illustrated as a translational misalignment, it will be understood that there may additionally or alternatively be a rotational misalignment.

[0579] Problems associated with misalignment may be minimized by increasing the width of the weld 70 so that the expected degree of misalignment does not place the joint outside the periphery of the second panel 2. Problems may also be minimized if the weld 70 is provided to extend beyond the overlap region of the panels to where only the first panel 1 would be in correct alignment. However, such a modification would be contrary to conventional teachings since it would increase, rather than minimize, the area of ​​the panel that receives the weld.

[0580] Even if the weld width is increased and the weld is positioned to extend beyond the overlap area, misalignment can reduce the total amount of bonded area of ​​the panels and therefore reduce their bond strength.

[0581] A further method of avoiding splice misalignment is shown in Figures 8A-8C. Figure 8A shows the same arrangement as Figure 7A, with the first panel 1 completely overlapping the second panel 2.

[0582] FIG. 8B shows the same panel with a weld 70 applied across the overlap region 21 and also extending beyond the overlap region onto the non-overlapping region of the first panel 1 .

[0583] Figure 8C shows the arrangement of Figure 8B, but with the weld and panel misaligned with respect to one another. Because the weld 70 is larger than the second panel 2, the misalignment can be corrected and the entire overlap region 21 is still welded. Additionally, because the weld 70 covers the entire area of ​​the second panel 2, not just the inner and outer perimeter boundaries of the second panel 2, the effect of the misalignment on the total weld area of ​​the overlap region can be reduced.

[0584] Therefore, it may be desirable to increase or maximize the weld area of ​​the headgear.

[0585] 9A and 9B show a welding apparatus 500, such as a radio frequency welder, for use in welding headgear panels.

[0586] Welding apparatus 500 includes upper and lower welding platens 501 and 502. Within the platens are upper die 503 and lower die 504. The platens are movable apart from one another to open the dies and together to bring the dies into close proximity for welding.

[0587] A panel, such as a first panel 1 and a second panel 2, is placed between the two dies.

[0588] The upper and lower dies each define a die face 506. These faces are brought into close proximity with the panel in between to effect fusion bonding of the panel.

[0589] Depending on the type of welding utilized, the die faces interact in various ways to effect the fusing of the panel materials therebetween. For example, in direct thermal welding, one or both of the dies may be heated to melt the panel that is pressed between them. Alternatively, in ultrasonic welding, vibration of the die face in contact with the panel heats the panel, resulting in the fusing of the panel.

[0590] In the example of radio frequency welding, an electromagnetic field provided across the die is of sufficient strength between the two die faces 506 to excite and melt the bipolar material located between those die faces.

[0591] For direct thermal welding, one or both of the dies may be heated, however, if other types of welding are used, such as ultrasonic or radio frequency welding, one or both of the dies may be heated as well.

[0592] If one or both dies are heated, they may be heated, for example, to about 100°C.

[0593] By heating one or both dies in this manner, the temperature of the panels may be increased prior to fusing, which may enhance the efficiency of the fusing operation.

[0594] One or both of the top die 503 and the bottom die 504 may include one or more recesses in the die away from the die face 506. As seen in Figures 9A and 9B, the top die 503 includes a recessed region 505. The recess creates a relatively increased distance between the two dies at the recessed region 505. This increased distance may reduce the degree of welding of the material within the footprint of the recessed region 505. It may also be that the material within the footprint of the recessed region remains unwelded or at least substantially unwelded.

[0595] For example, in the case of direct thermal welding, the upper die 503 may not contact the panel at the recessed area 505 and accordingly may not melt the panel at the recessed area. Similar functionality may be true for ultrasonic welding.

[0596] When the panels are fused by radio frequency welding, recesses 505 create an area of ​​reduced electromagnetic field strength, resulting in reduced heating of the panel at recesses 505. Recesses 505 may be of sufficient depth to prevent melting of one or more materials of the panel at recesses 505.

[0597] In this manner, the power supplied to the radio frequency welding device and the separation between the two die parts can be used to control where and to what extent the panels are fused.

[0598] The areas of the dies that are closest to each other during welding may fuse the portion of the panel between them, while the portion of the panel between the less-close portions of the two dies may remain less fused or unfused.

[0599] Thus, by designing one or both dies to engineer the shape of die face 506 and the location and depth of recessed area 505, it may be possible to control which portions of the headgear are fused and to what extent, and which portions of the headgear remain unfused.

[0600] The headgear panels are positioned within the welding apparatus 500 between an upper die 503 and a lower die 504. One or more of the panels may include alignment features 8, as described in connection with Figures 28A and 28B, that may interface with corresponding features on one or both of the dies to hold the panel or panels in a desired position relative to the dies.

[0601] Once the panels are in the desired position, the upper die 503 and lower die 504 may be brought together and welding of the panels begins.

[0602] FIG. 9B shows welding apparatus 500 in which platens 501 and 502 and dies 503 and 504 are brought together to weld panels 1 and 2 together.

[0603] The die may be positioned in a predetermined vicinity of one or more panels, and in some configurations, the die may apply pressure to one or more panels, or at least to the areas of the panels that are to be welded together.

[0604] Fusing of the panels can be provided in 2D, where the panels lie flat or substantially flat between two dies, as shown in Figures 9A and 9B.

[0605] The panels or portions of the panels may be welded in a 3D shape. For example, a die may have a complementary 3D shape so that the panels are pleated in a desired manner over the die. The panels may then be welded once pleated in the 3D shape. This may facilitate the formation of headgear having a 3D shape.

[0606] Although not shown in Figures 9A and 9B, one or more layers of a non-stick material, such as Teflon, may be provided between the panel and one or both dies to prevent the panel from sticking to the die or dies.

[0607] Although described using the example of high frequency welding, it will be appreciated that the panels may be fused together as described by any number of other methods of fusing, particularly plastic welding, including ultrasonic, vibration or friction welding, hot wedge welding, hot air welding or induction welding.

[0608] Figure 10 shows a patient 700 wearing headgear 10 to hold a patient interface 600 on the patient's face. The headgear 10 has an outer surface 4 that faces away from the patient in use, and an inner surface 5 (not visible in Figure 10) that faces and contacts the patient in use.

[0609] The outer and inner surfaces of the headgear can be the same or different from each other. The inner and outer surfaces of the headgear can be defined by panels having the same or different properties. For example, the surfaces can be differently colored or textured to indicate to the patient the orientation of the headgear.

[0610] As can be seen in Figure 10, the headgear 10 has a rear portion 100 that sits at the back of the patient's head. Two side straps are shown, an upper side strap 301 and a lower side strap 302. The side straps connect the headgear to a patient interface 600. As can be seen in Figure 10, the headgear also has a crown or top strap 200 that passes over the patient's head.

[0611] Two corresponding side straps, an upper side strap 303 and a lower side strap 304 , may connect to the hidden side of the patient interface 600 .

[0612] When there is a set of side straps on both sides, the area between the two side straps may define ear loops 320 as shown in FIG. 11. Ear loops 320 include the portion of the headgear that extends between each upper and lower side strap on one side of the headgear. Each upper strap 301, 303 passes over the ear and each lower strap 302, 304 passes under the ear. Ear loops 320 are located at least behind the ear. The edges of the ear loops between each upper and lower strap may be curved or may include multiple straight edges arranged around a nominal curve.

[0613] It will be appreciated that the straps may be provided in lengths sufficient to reach and engage the interface, either shorter or longer than those shown in FIGS. 10 and 11, to accommodate a range of different patient head sizes.

[0614] In other embodiments, the headgear 10 may include only two side straps, one strap connecting to each side of the interface.

[0615] FIG. 11 shows a top view of one embodiment of headgear 10.

[0616] The headgear 10 has a central region 15 and two lateral sides 16, 17. The central region 15 is located at the rear center of the patient's head, and the two lateral sides 16 and 17 extend around the patient's head toward each side of the patient interface for use.

[0617] As shown, the lateral sides 16 and 17 are shaped to fit around the patient's ears.

[0618] The height of the headgear, taken in a direction perpendicular to the lateral direction around the patient's head and indicated by line 807 in Fig. 11, is greater in the middle of central region 15 than in each of the laterally extending portions 16 and 17. In particular, as can be seen in Fig. 11, the laterally extending portions 16 and 17 narrow to about 30%-50% of the height of the headgear in the middle of central region 15.

[0619] As can be seen in FIG. 11, the height of the second panel 2 in the middle of the central region 15 and in the narrowed portion of the laterally extending portion is approximately equal, while the height of the first panel is greater in the central region 15 than in the narrowed portion of the laterally extending portion.

[0620] The headgear 10 has a rear portion 100 and a number of straps. Specifically, the headgear 10 has a pair of upper side straps 301 and 303 and a pair of lower side straps 302 and 304. The headgear also has an upper strap 200.

[0621] In another form, the headgear 10 may include a rear portion and two side straps for connecting to each side of the patient interface.

[0622] The strap may further be constructed of one or more panels identical to the rear portion.

[0623] One or more of the straps, or at least a portion of one or more, may be formed from one or more fused panels according to the present disclosure. Additionally or alternatively, the straps may be formed from another material, such as laminated foam. If the straps are not formed from one or more fused panels, the straps may be joined to the remainder of the headgear by being fused to one or more of the panels.

[0624] Although upper side straps 301 and 303 are each shown in FIG. 11 as being formed by the same panel as a respective portion of upper strap 200, each strap may be a separate piece.

[0625] In other configurations where there are two side straps on each side of the headgear, adjacent straps 301 and 302 and 303 and 304 may be formed from one or more of the same panels as one another. In yet other configurations, adjacent straps 301 and 302 and 303 and 304, respectively, and adjacent portions of top strap 200 may be formed from one or more of the same panels as one another.

[0626] Although shown as including two strap portions, the upper strap 200, in some forms, may be a single strap that attaches back to the rear portion 100 of the headgear.

[0627] In some configurations, one or more of the top straps 200 may be formed from one or more of the same panels as the rear portion 100 of the headgear. In such configurations, the side straps 301-304 may also be formed from one or more of the same panels as the rear portion of the headgear, or one or more of the side straps 301-304 may be separate pieces that are joined to the rear portion 100.

[0628] The headgear straps may include features 330 to facilitate tensioning the strap against the patient interface, or against itself in the case of the upper straps 200. Examples of such features 330 are shown in Figure 10. These features 330 may be, for example, one half of a hook and loop fastener, the other half of which may be provided by a surface of the headgear, such as a portion or rear portion of the strap.

[0629] Although the headgear may be shown without straps or other features for attachment to a patient interface, it will be understood that the headgear, or particularly the rear portion 100 of the headgear, may include any suitable number or arrangement of straps or other fastenings as desired to facilitate connection to and adjustment relative to the patient interface.

[0630] Figure 12 shows a first panel 1 and a second panel 2 that may form part of headgear 10 according to one embodiment. Both panels have a central region 15 and two lateral sides 16 and 17. The central region 15 of the second panel has a notch in its lower portion.

[0631] As can be seen in FIG. 12, the cutouts are located between the rear portion of the band 110 and the two lower strap connection portions 120a and 120b of the headgear.

[0632] The first panel 1 and the second panel 2 may be of the same material or of different materials. In particular, the first panel 1 may be more stretchable than the second panel.

[0633] Figure 13 shows panels 1 and 2 of Figure 12 superimposed on one another. The second panel 2 is disposed entirely within the first panel such that the overlap area 21 defined by the panels has the same dimensions as the second panel.

[0634] The overlapping panels define a first non-overlapping area 31 around the outer peripheral edge of the second panel where the protruding boundary of the first panel 1 is located, and a second non-overlapping area 32 in the central portion of the rear portion 200 defined by the cutout in the second panel 2.

[0635] The panels may be sized such that in one or both of the laterally extending portions 16 and 17, the height of the second panel may be about 70% to about 80% of the height of the first panel in that same portion.

[0636] The headgear may have only the thickness of the first panel 1 in the second non-overlapping region 32 , thereby defining a region that is thinner, i.e., more extensible, than the remainder of the overlap region 21 .

[0637] The lower extent of the rear portion is positioned around the upper part of the patient's neck so that the rear portion rests at the rear of the patient's head, an area that can have quite variable shapes between people of different sizes and therefore can be a point of discomfort for patients using a given headgear.

[0638] In various configurations where the first panel is a stretch material, the non-overlapping area 31 may function to stretch to accommodate the shape of the patient's neck. Thus, the non-overlapping area 31 in the cutout of the second panel 2 may be characterized as a stretch zone 80.

[0639] The stretch in the stretch zone 80 may be greater than the degree of stretch accommodated by at least adjacent portions of the headgear, and in particular may be greater than the degree of stretch accommodated by the overlap region 21 as seen in FIG.

[0640] According to various embodiments, the first panel 1 may completely overlap the second panel 2, while according to other embodiments, the first panel 1 may overlap the second panel only around the border of the cutout of the second panel 2. With such a configuration, the headgear may still provide the stretch functionality described above, but the first panel may be of a relatively small size.

[0641] The cutout in the second panel relative to the first panel may be substantially semicircular or crescent shaped to define a stretch zone 80, as seen in FIG.

[0642] The cutouts may increase in lateral size towards the bottom of the headgear, allowing for a relatively larger expansion towards the bottom of the headgear to accommodate larger lower neck sizes.

[0643] The first non-overlapping portion of the first panel 1 around the second panel 2 may be a free edge with no seams, and may have some edge treatment or no edge treatment.

[0644] In various configurations, the edge treatment of the panels may be provided by fusing one or more panels together.

[0645] The lack of seams and / or any edge treatments at the bottom edge can increase the comfort of the headgear for the patient by providing continuous properties such as stretch, stiffness and thickness throughout the portion of the first panel 1 that is overlapped with the second panel, all the way to the edge of the first panel.

[0646] The first panel 1 beyond the second panel 2 may be unsupported and may not be substantially load bearing, and may therefore roll or curl away from the patient's head upon contact with the patient's head, which may create a region of reduced pressure on the patient's head from the edge of the overlap region to the distal edge of the first panel 1.

[0647] Such a gradually decreasing pressure zone may have the effect of softening the edges and improve patient comfort, as opposed to a sudden drop in pressure across a hard edge which may make the patient more aware of the presence of the headgear or cause tissue pressure irritation at the edge.

[0648] The panels of rear portion 100 may be fused together to define headgear or portions thereof.

[0649] Figure 14 shows the rear portion 100 of Figure 13 where the panels have been fused together, such as by welds applied to the panels. As shown by the shading in Figure 14, the fused zone 41 covers the entire overlap area 21, such that all of the overlapping portions of the first panel 1 and the second panel 2 are fused together.

[0650] The first non-overlapping zone 31 of the boundary of the first panel is not fused and therefore may retain softer, more pliable or more stretchable properties than the fused panel of the fused zone 41 .

[0651] Such a configuration allows the headgear to retain a desired degree of comfort around its edges.

[0652] Although FIG. 14 shows a fused zone 41 extending across the entire overlap of the first and second panels, various embodiments of the headgear may utilize one or more non-fused zones.

[0653] Additionally, while the headgear of Figure 14 shows fused zones 41 covering only overlapped panels, various embodiments may incorporate fusion of all or part of the non-overlapping regions, which can have the advantage of tolerance to misalignment of panels or fusions, for example, as described in connection with Figures 7A-8C.

[0654] FIG. 15 shows the panels of FIG. 13 laid flat, showing the boundary 70 of the fused area extending beyond the periphery of the second panel 2.

[0655] 16 shows a close-up view of the top of central region 15 at the top of the second panel cutout. The fused boundary 70 is the margin or boundary that extends to and beyond the periphery of the second panel 2, to the outer perimeter edge of the second panel.

[0656] As shown in Figure 16 by boundary 70, the fusion will be applied both within the periphery of the second panel 2 and to the first panel 1 at the outer periphery of the second panel 2, resulting in a boundary between the periphery of the second panel 2 and boundary 70. As shown in Figure 16, the fusion will be applied to the entire area of ​​the second panel 2, not just the periphery of the second panel 2.

[0657] 16 as being located at the outer periphery of the second panel 2, the boundary 70 may be located anywhere between the outer periphery of the second panel and within the outer periphery of the second panel. For example, the boundary 70 may be located at the periphery of the second panel 2. If the boundary 70 is located within the periphery of the second panel 2, the boundary around the periphery of the second panel remains unfused.

[0658] The distance that boundary 70 extends beyond second panel 2 may be selected depending on the expected tolerance in positioning the panel relative to the fusing apparatus during manufacture of the headgear.

[0659] The size of the border can be continuous around the perimeter of the second panel. In other configurations, the size of the border can be variable around the perimeter of the second panel.

[0660] In some embodiments, the boundary 70 extending into the first panel 1 may result in fusing of the first panel, while in other embodiments the first panel 1 may be melted to a lesser extent than the second panel or not melted at all.

[0661] For example, a first panel may be made of a material that has a higher melting point than a second panel, and the first material may not be fused when the fusion bond is applied, provided that the temperature of the materials at which the fusion bond occurs does not exceed the melting point of the first material.

[0662] If the fusion is by radio frequency welding, the first panel may contain less or no bipolar material than the second panel and therefore may not be heated and melted by the radio frequency welding that may be applied to it.

[0663] According to at least some embodiments, the entire perimeter of one or all of the overlap regions of the headgear may be fused. Edges of the overlap regions where the overlapped panels are not bonded to one another may be unsightly. Unbonded edges of the overlap regions may also result in the potential for undesirable delamination in adjacent portions where the overlapped panels are fused to one another.

[0664] Thus, in some headgear embodiments, the entire periphery of each overlap region may be fused.

[0665] The rear portion 100 of the headgear may in some embodiments be configured to connect directly to a patient interface and may thus define the headgear. For example, the lateral ends of the rear portion 100 may be fitted with fasteners for attachment to a patient interface or may be adapted to couple with a patient interface, such as by applying an adhesive to one or both of the rear portion and the interface.

[0666] The rear portion 100 may be shaped, for example, as shown in Figure 13. The rear portion 100 may also have different shapes, such as a shape that may include one or more straps formed from one or more of the panels that make up the rear portion 100.

[0667] In other embodiments, one or more straps may be associated with the rear portion to provide headgear 10. The straps may be associated with the rear portion 100 by any suitable method, such as by fusing, gluing, or sewing.

[0668] When the panels of the rear portion 100 are fused together, it may be desirable to join the straps to the rear portion by fusion. This may be done in a separate step where the straps are fused to the already fused rear portion. It may also be done in a single step, where the panels of the rear portion and the straps, whether panels or other materials such as foam fabric-foam laminate, are all fused together in one operation.

[0669] FIG. 17A shows another embodiment of a rear portion 100 of headgear 10 in which the overlap region includes a fused zone 41 and a plurality of unfused zones 51-54.

[0670] According to some embodiments, the non-fused zones may be generally located in portions of the headgear that have a relatively increased height. In this manner, the non-fused zones may be provided while still maintaining an amount of fused area across the lateral dimensions of the headgear. Figure 17A shows an example of this, where a continuous fused band is provided along at least a substantial portion of the elongated direction of the headgear.

[0671] The headgear may define a band 110 and a number of strap connection portions 120. An example of headgear having a band 110 is shown in FIG. 17A. The band 110 is part of the headgear and extends around the patient's head and transfers a load between at least two connection points to the patient interface. The strap connection portions 120a-d depend from the band and the straps are defined in whole or in part by one or more of the same panels or are connected to the panels, such as by being fused together.

[0672] It will be appreciated that where the strap is defined partially or wholly by one or more of the headgear panels at the strap connection portion 120, the shape of the first panel 1 and / or the second panel 2 may be adapted from, for example, those shown in any one of Figures 13-17.

[0673] As can be seen in FIG. 17A, the majority of the headgear in band 110 is fused zone 41, and the strap connection portions are non-fused zones 51-54.

[0674] With this configuration, the headgear may have relatively low stretch bands that can transfer loads between the sides of the headgear and relatively high stretch areas where the straps connect, which may allow stretching to accommodate different patient physiological conditions or different tensions in the straps.

[0675] FIG. 17B shows the rear portion 100 of FIG. 17A joined to a number of straps 301 - 304 and 200 .

[0676] As seen in FIG. 17B, the straps are sandwiched between the first and second panels at each of the strap connection portions 120, and the first panel, each strap, and the second panel are all fused to one another at their overlapping portions.

[0677] As seen in FIG. 17B, fusion of the headgear at strap connection portion 120 results in each of the first panel 1 and second panel 2 being fused to a respective side of a respective strap.

[0678] Sandwiching the strap between a first layer 1 and a second layer 2 can provide the benefits of the double overlap joint mentioned above and the resulting ability to reduce twisting at the joint under the strap load.

[0679] The headgear 10 as shown in Figure 17B may be formed first as the rear portion 100 of Figure 17A and then the straps joined as a separate step. In another form, one or more of the straps may be joined to the respective panels in the same step that some or all of the panels are fused to form the rear portion 100 of Figure 17A.

[0680] As seen in Figure 17B, when the straps are fused to the rear portion, they provide a continuous peripheral edge of the fused second panel 2. This prevents a loose edge of the second panel that could allow delamination of the first and second panels.

[0681] It will be understood that any of the embodiments of the rear portion 100 described herein having non-fused zones of overlapping panels at the strap connection portions may be wholly or partially fused thereto once the straps are joined.

[0682] Another embodiment of the rear portion 100 is shown in FIG. 18, in which the non-fused zones 51 - 54 are all enclosed within the uninterrupted fused zone 41 of the overlapping panels 1 and 2 .

[0683] The fused zone or zones may be discrete, or two or more fused zones may define an uninterrupted fused region, as seen in FIG.

[0684] Because loads can be transferred from the straps to the fused strap connections and then through the fused portions of the headgear bands, the surrounding fused portions of the panel can have an effect on how loads are transferred through the headgear.

[0685] This may provide a rear portion of the headgear that is relatively less compliant overall than that of the embodiment of Figures 17A and 17B.

[0686] 18 may have relatively greater stretchability than fused zone 41. By locating non-fused zones 51-54 at the widest portions of the overlap region, the overall resistance to stretching of the overlap region in those portions may be reduced.

[0687] Aside from the stretch zone 80, the size of the non-overlapping portion of the first panel 1 may be the same or substantially the same for the remainder of the non-overlapping portion of the first panel. Alternatively, the size of the non-overlapping portion of the first panel outside of the stretch zone 80 may vary. For example, the amount of non-overlapping of the first panel 1 at the ear loops 320 may be greater or less than the amount of non-overlapping of the first panel 1 on the opposite side of the headgear near the top of the band portion 110 of the headgear.

[0688] The size of the non-overlapping portion of the first panel 1 around the second panel 2 may be referred to as the boundary of the first panel. As seen in the configuration of Figure 18, the boundary formed by the non-overlapping portion of the first panel 1 around the ear loops 320 and along the top edge of the back portion 100 is of substantially continuous width.

[0689] While the borders around the top edge of the ear loops 320 and rear portion 100 in FIG. 18 are substantially the same size, in other configurations the borders may be different widths in different regions. Customizing the width of the borders of the non-overlapping panels may provide localized variation in the softness of the edges of the headgear when worn. If the first panel is a stretch material, controlling the width of the borders of the non-overlapping panels in different regions may allow for controlled and restored deformation along the borders, such as may occur in the stretch zones 80.

[0690] For example, in some configurations, the first panel 1 may have a locally increased width of the non-overlapping border at or part of the ear loops 320. This may act to prevent or limit lifting of the headgear from the patient's head when worn.

[0691] 18-1 and 18-2 are respectively a top view of another embodiment of the headgear 10 and a partial rear view of the headgear 10 when worn. As can be seen in FIG. 18-1, the non-overlapping portion of the first panel 1 on the side of the ear loop adjacent the elastic zone 80 has a locally increased width.

[0692] The non-overlapping portion of the first panel 1 between each strap connection portion 120 and the band 110 has a larger radius of curvature such that the non-overlapping portion between the connection portion 120 and the band 110 defines a crescent shape.

[0693] 18-2, when worn on a patient, forces acting on the headgear 10 may, at least in some circumstances, urge the headgear to lift off the patient's head behind the patient's ears at or towards the base of the curve between the strap connection portions 120 and the band 110. When the headgear is subjected to such forces, the locally widened portions of the non-overlapping first panel may help to limit or prevent the headgear from lifting off the patient's head between the strap connection portions 120 and the band 110.

[0694] 18-3 illustrates four different configurations 100a-d of the rear portion 100 of the headgear 10. Each of the rear portions 100a-d has a first panel 1 partially overlapped by a second panel 2, with the non-overlapping portions of each first panel 1 forming boundaries for various portions of the periphery of the rear portion. In particular, the non-overlapping portions define boundaries at the rear stretch zone 80 and boundaries 83 at the ear loops 320.

[0695] Each of the rear portions 100a-d shows a different configuration of the width of the non-overlapping border of the first panel 1 at the ear loop 320. Such different width of the border can be provided by increasing the local size of the first panel 1 or decreasing the local width of the overlapping second panel 2 as in the configuration of Fig. 18-3. In each progressive one of the rear portions 100a-d, the second panel 2 at the ear loop 320 has a relatively reduced width. In the case of the rear portion 100a, the border 83 is about half the width of the adjacent portion of the second panel 2. In the case of the rear portion 100b, the border 83 is about the same width as the adjacent portion of the second panel 2. In the case of the rear portion 100c, the border 83 is about twice the width of the adjacent portion of the second panel 2. Finally, in the case of the rear portion 100d, the border 83 is about three times the width of the adjacent portion of the second panel 2.

[0696] If the first panel 1 is a stretchable panel and the second panel 2 is a non-stretchable panel, reducing the width of the second panel 2 at the ear loops 320 may increase the ability of the headgear to conform to the shape of the patient's head in this area.

[0697] Another embodiment of headgear is shown in Figure 19. In Figure 19, substantially the entire overlapping portion of the headgear is fused to define a fused zone 41. As previously discussed, it will be understood that the fused zone 41 may extend beyond the second panel 2 and encompass some or all of the non-overlapping area of ​​the first panel 1.

[0698] The headgear of Figure 19 has non-fused zones 51-54 provided as a cluster of multiple smaller zones. As seen in Figure 19, each smaller zone is circular, which may minimize tight geometries and accordingly reduce the risk of arcing or burning of the panels near the boundaries of each smaller non-fused zone and the fused zone.

[0699] Where fusing results in one or more fused panels thinning or flattening, the configuration of FIG. 19 provides a headgear surface having clusters of raised points or protrusions in each of the groups of non-fused zones 51-54.

[0700] This may provide a tactile feature for the user, such as helping the user determine the orientation of the headgear by feeling the raised protrusions.

[0701] Clusters of small adjacent non-fused zones may also act together to form stretch zones that make the headgear relatively more compliant.

[0702] The raised protrusions in the non-fused zones may be more pronounced on one or the other of the inner and outer surfaces of the headgear due to the selection of different panel materials. For example, if the outer surface panels are compressed more by fusing than the inner surface panels, relatively more pronounced protrusions may be formed on the outer surface of the headgear than on the inner surface.

[0703] It may be desirable to manufacture a single size of headgear, or at least a minimum number of different sizes. It may also be desirable for a given headgear size to accommodate a wide range of patients.

[0704] Headgear of a given size may have particular dimensions and proportions of the rear portion 100 and particular strap lengths.

[0705] To increase the ability of a given headgear size to accommodate different patient shapes, the straps may be lengthened. This may allow the headgear to fit patients with larger shapes. However, straps long enough to accommodate a larger patient may cause problems for users of the same size headgear with a smaller shape.

[0706] For example, if the strap ends are secured by fasteners on or in the straps, such as by a hook or loop portion of the strap end being connected to another of the strap's hook or loop portions, the strap ends may return beyond the base of the strap for smaller shaped patients, so that a given size of headgear may not be suitable for smaller shaped patients.

[0707] If the panel is a non-broken loop material and the fusion process is such that it reduces the density of the non-broken loops at the surface of the non-broken loop material, one or more non-fused zones may be utilized to maintain the area of ​​non-broken loops, which may allow, for example, to secure a strap fastener to headgear at the non-fused zone or zones.

[0708] For example, as seen in FIG. 19, a cluster of small unfused portions of the headgear in each of the unfused zones 51-54 may provide a sufficient density of non-broken loops to enable a strap fastener having a hook portion of a hook-and-loop fastener to be secured to the headgear in one or each of the unfused zones 51-54.

[0709] The location of the non-fused zone or zones may be such as to provide an extension of the area to which the strap fastener may be secured.

[0710] 17B, ​​the first non-fused zone 51 and the fourth non-fused zone 54 are located along extensions of portions of respective straps 301 and 200 and 303 and 200, respectively. Similarly, at least a portion of the second non-fused zone 52 and the third non-fused zone 53 are located along extensions of respective straps 302 and 304.

[0711] The non-fused zones may be positioned along an extension from the straps at their respective strap connection portions 120 or along an extension from any other distal portion of the straps, although it will be understood that the non-fused zones may be located anywhere on the headgear corresponding to where it is desired that a user can attach a strap fastener.

[0712] The rear portion 100 of Figure 18 shows further examples of unfused portions 51-54 where strap fasteners may be attached. As can be seen in Figure 18, the intermediate unfused portions 52 and 53 encompass a significant portion of the overlapping portions of the panels adjacent the strap connection portions.

[0713] As also shown in FIG. 18, fusion zones 51-54 are shaped to increase along an expected extension from where the strap would be connected to its strap connection portion, as shown for the strap in FIG. 17B.

[0714] The non-fused zone, to which the strap can be attached, may be located immediately adjacent the base of the strap.

[0715] In configurations where there is a continuous perimeter of overlapping panels that are fused together, one or more non-fused zones may be located within the fused perimeter but as close as possible to the base of the straps, thereby avoiding or minimizing strap lengths where the strap fasteners cannot be secured to a non-fused zone.

[0716] In other configurations, there may be a fused portion of the panel located between the base of the strap and the unfused zone, as illustrated by the portion of fused zone 41 between strap 302 and unfused zone 52 in Figure 17B.

[0717] If there is a fused zone between the base of the strap and a non-fused zone of the headgear to which the strap end can be connected, the fasteners of the strap ends can be sized to span the gap between the strap base and the non-fused zone. For example, in the configuration of FIG. 17B, the strap fasteners of strap 302 can be sized larger than the dimension of the fused zone 41 between the base of strap 302 and non-fused zone 52 along the length of the strap.

[0718] FIG. 20 shows a die configuration for a welding apparatus 500, for example either an upper die 503 or a lower die 504, for use in fusing headgear as shown in FIG.

[0719] 20, the die 503 has a die face 506 that corresponds to the size and shape of the desired fused zone 41 of the headgear. A number of small circular areas 505 are recessed from the die face 506. In these recesses, the die may press less hard or not against adjacent panels of the headgear during fusing. This may result in either or both of reduced compression of the panels adjacent the die at the recesses and reduced welding or unwelding of one or more panels at the recesses.

[0720] FIG. 21 shows a further embodiment of fused headgear, and FIG. 22 shows one example of a die 503 that can be used to manufacture the fused headgear of FIG.

[0721] As previously mentioned, the headgear may have a transition zone of one or more fused panels, where the degree of fusion of one or more panels may transition between an unfused zone and a fused zone.

[0722] A transition zone may be located between the non-fused zone and the fused zone.

[0723] In other configurations, a transition zone may be provided within a non-fused zone or within a fused zone, or between two non-fused zones or between two fused zones, In such cases, the transition zone may define an area of ​​partial fusion of one or more panels.

[0724] FIG. 21 shows fused headgear 10 having a fused zone 41 across the band portion of the headgear and four non-fused zones 51-54 at the strap connection portions of the headgear.

[0725] The headgear also has a set of second fused zones 42a-d provided as clusters of small individual zones. These are the inverse of the non-fused zones of the headgear of Figure 19 and instead define spots of fused material.

[0726] These may be formed, for example, by spot welding of the headgear.

[0727] If the panel is compressed or thinned as it is fused, the second fused zone 42 will define a spot-like depression or recess in the headgear.

[0728] 21, the lateral second non-fused zones 42a and 42d are generally triangular in shape and taper inwardly towards the central portion of the headgear, with the base of the triangle located adjacent the respective strap connection portions 51 and 54 and the tip of the triangle located away from the respective strap connection portions 51 and 54.

[0729] As can be seen in FIG. 21, the narrowed portions of the second non-fused zones 42a and 52b are located within transition zones 61 and 64, respectively.

[0730] The second non-fused zones 42b and 42c are also substantially triangular in shape, however, unlike the second non-fused zones 42a and 42d, the second non-fused zones 42b and 42c are oriented such that their narrowed portions are located toward the associated strap connection portions 52 and 53 and their opposing bases are located toward the headgear band.

[0731] As can be seen in FIG. 21, the wider portions of second non-fused zones 42b and 42c are located further into transition zones 62 and 63 than the narrower portions of second non-fused zones 42a and 42d relative to their respective transition zones 61 and 64.

[0732] As can be seen in FIG. 21, the second non-fused zones 42a and 42d are larger in size adjacent the respective strap connection portions 51 and 54 than the second non-fused zones 42b and 42c adjacent the respective strap connection portions 52 and 53.

[0733] The size of the fused zone, which is made up of clusters of smaller fused portions or spots, may be larger or smaller than that shown in Figure 21. Similarly, the size of the smaller fused portions and their proximity to each other may be larger or smaller than that shown in Figure 21.

[0734] When a cluster of smaller fused portions make up the fused zone, the fused portions may be uniform or non-uniform in size and relative position to one another.

[0735] Each smaller fused portion may be fused to the same extent, as seen in the diagram of Figure 21. Alternatively, one or more smaller fused portions may be fused to a relatively greater or lesser extent. As with the transition zone, the degree of fusion of the smaller fused portions may vary across a fused zone comprised of a cluster of smaller fused portions. For example, the degree of fusion may decrease toward one or more sides of the fused zone, or decrease toward the entire periphery or periphery of the fused zone.

[0736] The size and shape of the small fused portions within fused zone 42 as well as their density and arrangement can be such as to provide a desired pattern or texture to the headgear or one or more portions of the headgear.

[0737] The configuration of fused and non-fused zones can be utilized to customize and specifically localize headgear properties such as breathability, moisture wicking capacity, edge characteristics, hand, feel, and stretch and recovery, especially when patterns of fused or non-fused zones are used.

[0738] For example, clusters of fused spots can be used to give the headgear a waffle texture, particularly where the fusion of the headgear compresses or thins the headgear at the fused portions. Such a waffle texture can include a pattern of recessed spots. Similarly, clusters of unfused spots can be used to give the headgear a reverse waffle texture.

[0739] 21 further includes four transition zones 61-64, each located between an associated one of the non-fused zones 51-56 and a portion of the fused zone 41.

[0740] In each of the transition regions 61-64, as indicated by the lower shading density, the first panel 1 and the second panel 2 can be fused to one another to a degree between that of the fused zone 41 and that of any of the non-fused zones 51-54.

[0741] The transition zone may define a single degree of fusion, for example, such that the panels are fused together with approximately half the peel strength of the fused zone.

[0742] The shapes of the transition zones 61-64 can vary. As shown in Figure 21, the size of the transition zones 61 and 64 varies from narrower at the more central portion of the headgear to a wider configuration at the unfused ends. Conversely, as shown in Figure 21, the transition zones 62 and 63 have their widest dimension at the most central portion of the headgear.

[0743] Alternatively, the transition zone may define a gradient in the degree of fusion. For example, as seen in FIG. 21, the transition zone 62 may have a first, relatively lesser degree of fusion adjacent the non-fused zone 52 and a second, relatively greater degree of fusion adjacent the fused zone 41.

[0744] If the degree of fusion varies across the transition zone, it may vary in a step or with a gradient. The gradient may be continuous or may vary across the transition zone.

[0745] The use of a transition zone can provide a smoothing effect between the properties of adjacent fused and unfused zones, especially if the degree of fusion varies across the transition zone.

[0746] For example, if one or more of the thickness, extensibility, recovery, softness, or surface texture of one or more panels is altered by fusing, the transition zone may grade the transition between these different properties, which may provide one or more of improved performance, improved comfort, or improved feel of the headgear.

[0747] Headgear comfort and performance can be particularly affected by the use of transition zones. Transitions between different regions of the headgear, for example between a relatively inextensible, load-bearing portion of the headgear and an adjacent relatively extensible portion, can induce pressure concentrations at the interface when the headgear is placed on a patient. Even if pressure concentrations are not induced, abrupt transitions between regions of different properties can create a pressure sensation for the patient along the interface.

[0748] In this manner, the transition zone may allow for a gradual change in headgear characteristics between two different regions, which may accordingly increase patient comfort.

[0749] In use, loads may be applied from the strap connections in the non-fused zones 51-54 and transferred to the headgear bands at the fused zone 41. Thus, the location of the transition zones 61-64 of the headgear in Figure 21 is between the non-fused and fused zones and may therefore provide a gradation in at least the extensibility of the headgear along the load transfer path.

[0750] Various versions of the headgear 10 of FIG. 21 may or may not include one or more of the set of second fused zones 42.

[0751] 21 embodiment, the set of second fused zones 42 may act to secure the panels together at their portions in the associated unfused zones 51-54 and transition zones 61-64, which may prevent undesired separation of the first and second panels.

[0752] A set of second fused zones 42 may additionally or alternatively act as transition elements, effectively increasing the density or average degree of fusion of the fused regions within the associated non-fused zones 51-54 and transition zones 61-64.

[0753] 21 may have one or more straps attached. For example, side straps 301-304 and potentially also top strap 200 may be attached to headgear 10 at one or more of strap connection portions 120.

[0754] The strap or straps may be attached to the panels in the rear portion of the headgear by any desired method, such as by fusing, adhesive, or using fasteners.

[0755] According to some embodiments, the straps may be fused to one or both of the first panel 1 and the second panel 2 .

[0756] In particular, as seen in the configuration of FIG. 21, one or more straps, such as those shown in FIG. 11, may be sandwiched between the free ends of the first panel 1 and the second panel 2 in the non-overlapping regions 51-54, and the panels and straps may be fused to one another.

[0757] Although the rear portion of the headgear is shown in FIG. 21 as being fused prior to attachment of the straps, it will be understood that the step of fusing the straps to the rear portion may be integrated with the step of fusing the panels of the rear portion.

[0758] FIG. 22 shows a welding die 503 used to fuse the rear portion of headgear similar to that of FIG.

[0759] 22, the die has a die face 506 that corresponds to the fused zone 41. It also has four recessed areas 505 that correspond to the four non-fused zones 51-54. The headgear transition zones 61-64 are defined by sloped transition areas 509 of the die that gradually change from the level of the recessed areas 505 to the level of the die face 506.

[0760] A set of second fusion zones 42 is at the level of the die face 506 and is defined by a number of posts 507 defined by recesses in the die.

[0761] The posts 507 may be raised to the same level as the die surface 506 .

[0762] The posts 507 may extend to a level between the recess level 505 and the die face 506 .

[0763] The posts 507 may all be the same height, or alternatively, one or more of the posts may be of different heights.

[0764] In particular, the height of the posts may vary from the side of each second fused zone adjacent the non-fused zone to the side of each second fused zone adjacent the fused zone, for example, the height of the posts may increase toward the fused zone such that the degree of fusion at the posts increases toward the fused zone.

[0765] Headgear transition zones may have a gradient in the degree of fusion in one direction, as shown in headgear transition zones 61-64 in Figure 21, where the degree of fusion increases in a direction away from the adjacent unfused zone and increases in the headgear bands toward the fused zone.

[0766] However, it may be desirable to provide a gradient in the degree of fusion from any adjacent portion of either the unfused zone or the fused zone or both.

[0767] FIG. 23 shows an example of headgear 10 having a similar configuration to that of FIG. 21, but in which the transition zones 61-64 have a fusion gradient over their entire circumference.

[0768] A die for manufacturing headgear in the configuration of Figure 23 is shown in Figure 24. In Figure 24, transition regions 509 define a smooth curve in die height between recessed regions 505 and die faces 506, respectively.

[0769] Headgear manufactured with such a die may be more comfortable because any transitions between welded and non-welded portions of the headgear with different properties may be gradual rather than abrupt.

[0770] The headgear may include one or more user-identifiable indicia, such as a brand, model name or number, size information, serial number, regulatory information, or other such features. Such indicia may be additionally applied to the headgear conventionally, for example, by sewing or gluing a label.

[0771] FIG. 25 illustrates another die for use in manufacturing headgear. Die 503 of FIG. 25 further includes a set of indicia features 508. Indicia features 508 are a combination of areas at die face 506, recess heights, and potentially various transition heights therebetween. Such a combination of features may result in one or more indicia features being formed in the headgear when the panels are fused. The indicia may be discernible from the resulting combination of fused zones, unfused zones, and potentially transition zones. For example, if the panels are thinned when fused, they may be discernible from a combination of relatively higher and lower portions of the headgear.

[0772] If fusing changes the color or surface texture of the panels, the indicia may additionally or alternatively be distinguishable through the difference in these features.

[0773] It will be appreciated that the indicia features 508 of the die define in relief the features of the resulting indicia on the headgear and the recesses of the die define the relatively raised portions of the headgear, and vice versa.

[0774] FIG. 26 shows a partial view of fused headgear 10 having indicia 9 formed by fusion with a die having indicia features 508, such as the die features of FIG.

[0775] As can be seen in FIG. 26, indicium 9 is defined by a non-fused zone 51 and separate fused zones 41-43 which form the shape of the constituent characters or symbols (in this case a brand) of the indicium.

[0776] In other configurations, the indicium 9 may be formed without a peripheral differentiation portion, such as non-fused zone 51 in Fig. 26. In such cases, the constituent letters or symbols of the indicium may be defined by the non-fused zone so as to differentiate the peripheral fused portion of the headgear.

[0777] The application of the indicia by fusing the panels may be done as a separate step from fusing the panels to join them together.

[0778] In various embodiments, the formation of the indicia may occur in the same step as the fusing of the panels to join them together, which may allow for simplification of the manufacturing process since the indicia do not have to be provided as a separate manufacturing step.

[0779] 26 as being intermediate the central region 15 of the headgear 10 and within the fused zone, it will be understood that the indicia 9 may be provided at any desired location on the headgear. Similarly, the headgear may be fused to present indicia on either or both of the inner or outer surfaces of the headgear.

[0780] In addition to or instead of forming the indicium by selective fusing one or more panels, the indicium may be formed by selectively removing material from one or more panels.

[0781] For example, FIG. 26-1A shows headgear 10 including indicium 9. FIG. 26-1B shows a cross section through line AA of FIG. 26-1A. As seen in FIG. 26-1B, the headgear in cross section has a first panel 1 partially overlapped by a second panel 2. However, the first panel 1 has had material removed to form the shape of indicium 9. The first panel 1 and second panel 2 are fused together to define indicium 9 embossed through the removed material.

[0782] Such a configuration may provide clearly visible indicia, especially where the first panel 1 and second panel 2 are of different colors or surface textures.

[0783] 27 shows another embodiment of headgear 10 including fused indicia 9. Headgear 10 has non-fused zones 51 and 52 at strap connection portions 120a and 120b at the lateral ends of the headgear, and is fused at the two more central strap connection portions 120c and 120d.

[0784] Above the strap connection portions 120c and 120d are two large non-fused zones 53 and 54.

[0785] Indicia 9 is located in the center of the overlapping portion of first panel 1 and second panel 2 above the cutout in second panel 2 .

[0786] As previously discussed, one or more straps may be attached to the headgear of Fig. 27. While the first and second panels are fused together at lower strap connection portions 120c and 120d, the fused panels may be overlapped against the straps and fused together with the straps.

[0787] The panels forming the headgear may need to be positioned in specific locations within the welding apparatus relative to each other and relative to the dies of the welding apparatus to provide the desired configuration of overlapping and non-overlapping regions of the headgear and to provide the desired locations of the fused and non-fused zones.

[0788] Thus, it may be desirable to include one or more positioning features on or in one or more of the panels to align them with each other and with one or both of the dies, or to align them with each other and with one or both of the dies.

[0789] 28A shows one embodiment of a headgear stack prior to fusion. The stack includes a first panel and a fully overlapping second panel 2. The first panel 1 includes a number of alignment features 8 disposed on a sacrificial portion 7 of the first layer.

[0790] The alignment features, which are holes in the embodiment of Figure 28A, may mate with corresponding features in one or more dies of a welding apparatus, which may allow the first panel to be positioned in a desired position relative to the dies.

[0791] One or more of the panels of the stack may include such alignment features. For example, both the first panel 1 and the second panel 2 may include alignment features. The alignment features may be discrete or may overlap one another when the panels are stacked in their intended positions. For example, both the first panel and the second panel may have alignment features that remain together when the panels are positioned relative to one another in their desired positions. With this configuration, the panels may be positioned relative to the die and the panels may be positioned relative to one another.

[0792] In some forms, the sacrificial portion 7 may itself act as an alignment feature, for example by aligning with a portion of one or more die.

[0793] The sacrificial portion 7 is separated from the panel or panels before production of the headgear is completed. Separation of the sacrificial portion can be, for example, by stamping or cutting the sacrificial portion from the remainder of the panel or panels.

[0794] In some forms, the sacrificial portions may be punched to separate them from the panels, and the punching step may be integrated with the step of fusing the panels together, and for this purpose the die may include a cut surface that may act on the panels when the die is brought together to fuse the panels together.

[0795] In another form, the sacrificial portion may be separated by melting or burning the panel during fusing of the panel, for example in the case of high frequency welding, by allowing an arc discharge between the dies which separates the sacrificial portion from the remainder of the panel.

[0796] In some embodiments, the alignment features 9 may not be provided on the sacrificial portion that is removed from the stack, but instead are provided on or in the rear portion of the headgear itself. For example, one or both of the panels may include one or more holes for alignment of the panels, which remain features of the headgear when the headgear is fused.

[0797] Figure 28B shows the headgear 10 of Figure 28A after it has been fused and stamped out. The headgear includes a main fused zone 41, a set of spot welds 42, and four unfused zones 51-54.

[0798] As discussed above, punching or cutting may be employed to separate a sacrificial portion from the headgear that facilitates alignment of one or more panels, although other portions of the headgear may additionally or alternatively be punched or cut.

[0799] Thus, the headgear may have material removed therefrom by cutting or punching, which may include either or both of removing a peripheral portion of one or more panels and removing an interior portion of one or more panels.

[0800] For example, portions of the overlap regions, particularly the fused zones of the overlap regions, may be removed from the headgear. Removal of these portions may, for example, reduce the weight of the headgear. Removal of portions may also improve the breathability of the headgear.

[0801] One or more cuts or die cuts in the panels of the headgear may also be configured to form one or more indicia, such as a brand, model name or number, size information, serial number, regulatory information, or other such features.

[0802] The indicium may be formed by cutting or punching one or more of the panels of the headgear to create one or more holes in the headgear in the shape of the indicium.

[0803] Additionally or alternatively, indicia may be formed by removing a portion of one layer in the overlap region. The indicia may be discernible from a feature on the surface of the headgear where material has been removed. If the overlapped layers are of different colors or textures, the indicia may be discernible by color or texture.

[0804] If the indicia are cut or punched into one panel at the overlap region, it may be possible to provide indicia that is discernible, or at least primarily discernible, from only one side of the headgear. For example, if the panel closest to the user on the inner surface of the headgear is punched, and the adjacent panel or panels toward or on the outer surface are not punched, the indicia may appear only on the inner surface of the headgear.

[0805] Any removed portions of the headgear may be removed prior to fusing the headgear.

[0806] Portions of the headgear may be removed in the same step as the headgear fusion, such as by stamping out the headgear as the fusion is applied.

[0807] In other forms, portions of the headgear may be removed after fusing the panels by die cutting or other suitable methods.

[0808] In configurations where there are fused peripheries of one or more overlap regions and removal of a portion of the headgear occurs in conjunction with or after the step of fusing the panels, the fused peripheries of the one or more overlap regions can be maintained by removing material only within the fused zones.

[0809] The portion removed from the headgear may be of any suitable size and shape.

[0810] Fig. 40A shows the headgear 10 of Fig. 17B joined with multiple straps 301-304 and 200. The headgear 10 of Fig. 40A shows how the headgear can be punched through both the first layer 1 and the second layer 2.

[0811] As seen in FIG. 40A, the headgear includes a cluster of first cutouts 91 of a first size and a cluster of second cutouts 92 of a second, larger size.

[0812] Cutouts 91 and 92 in FIG. 40A extend through both the first panel 1 and the second panel 2, defining a cutout that extends entirely through the headgear.

[0813] Such cutouts may reduce the weight of the headgear. They may also increase the breathability of the headgear.

[0814] The notches 91 and 92 in FIG. 40A may be provided separately in each of the first and second panels prior to fusing.

[0815] The notches 92 and 92 in FIG. 40A may be provided in the first and second panels prior to being fused, as part of the fusion process, or together after being fused.

[0816] 40A shows cutouts in lateral portions of band 110, it will be understood that the cutouts may be provided in any desired location on the headgear, particularly where it is desired to increase the breathability of the headgear. Likewise, it will be understood that single cutouts or clusters of cutouts may be provided in any number of desired sizes and groupings.

[0817] Figure 40B shows the headgear of Figure 40A but with a different cutout configuration. As can be seen in Figure 40A, the headgear has a plurality of first cutouts 91 in the second layer 2. Within the first cutouts 91 there are second cutouts 92 of relatively small size in each of the underlying first panels 1.

[0818] This configuration may provide increased weight reduction compared to smaller notch 92 sized through holes.

[0819] Where the first panel 1 is more stretchable than the second panel 2, the configuration of FIG. 40B may also provide localized areas of increased stretchability within each cutout 91 of the second panel 2.

[0820] The larger cutouts may be formed in the associated panels before the panels are stacked together, while the smaller cutouts that extend through both panels may be formed after the panels are stacked together, either before, during or after the panels are fused together.

[0821] Figure 40C shows another embodiment of headgear having cutouts. Figure 40C shows the rear portion 100 of Figure 13, but from the opposite side. For example, Figure 13 shows the outside view of the headgear, while Figure 40C shows the inside of the headgear facing the patient.

[0822] In FIG. 40C, the extent of the second panel 2 superimposed underneath is indicated by a dashed line.

[0823] As can be seen in Figure 40C, there are a number of first cutouts 91 in the first panel. Among these are second cutouts 92 of smaller size in the second panel 2. This is the opposite of the configuration in Figure 40B.

[0824] In FIG. 40C, the notches 92 each define a hole through the headgear.

[0825] Also shown in Figure 40C are a number of third cutouts 93. These are cutouts in the first layer 1 that expose areas of the second layer 2, but do not define holes through the headgear.

[0826] Headgear according to the present disclosure may provide one or more elastic zones 80. In the elastic regions, the headgear may provide relatively greater extensibility than adjacent portions of the headgear. The shape, size, and location of such elastic regions may customize the function of the headgear. For example, the elastic regions may be oriented to allow additional extensibility in one direction of the headgear but not in another direction. The elastic regions may be configured to induce relative rotation in portions of the headgear on either side of the elastic region when a load is applied across the elastic region.

[0827] 29 shows an embodiment of headgear made of a first panel, a second panel 2a, a third panel 2b, and a fourth panel 2c fused to the first panel. The second, third, and fourth panels may each be the same material, or may be made of two or three different materials.

[0828] A third panel 2b and a fourth panel 2c are laterally spaced from the second panel 2a and disposed on the first panel 1. The gaps between the panels define first and second stretch zones 81 and 82.

[0829] In the elastic zones 81 and 82, the headgear is comprised only of the first panel 1. As described in various other embodiments, the first panel may be of a relatively more extensible material than the second (and third and fourth) panels, or may be of a material that is slightly more extensible, at least in its non-overlapping areas where the elastic zones are, than in the overlapping areas where the panels are fused.

[0830] As can be seen in FIG. 29, the elastic zones 81 and 82 are of substantially continuous lateral size and extend across the full height of the band of the headgear.

[0831] When a load is applied across the headgear in the direction of arrows 801 and 802 , the headgear may stretch and expand in that direction, at least in part due to stretching at the elastic zones 81 and 82 .

[0832] It may be desirable to provide different amounts of extensibility in different portions of the headgear to allow the headgear to stretch into shapes different from its flat configuration.

[0833] For example, it may be desirable for the headgear to be stretched so that an upper portion of the headgear is relatively wider than a lower portion of the headgear.

[0834] FIG. 30 shows one embodiment of headgear 10 in which two elastic zones 81 and 82 are configured to allow greater stretch toward the top of the headgear band than toward the bottom.

[0835] 30, the elastic zones 80 and 81 are wider towards the top of the band than at the bottom, so that when loaded in the direction of arrows 801 and 802, the lateral ends of the headgear beyond the elastic zones 81 and 82 can rotate at least somewhat in the direction of arrows 803 and 804.

[0836] Allowing more stretch in portions of the headgear 10 may be desirable to facilitate certain patient movements. For example, when a patient wearing the headgear lowers or raises his or her head, the distance between the top of the rear portion of the headgear and the top attachment point to the patient interface and the distance between the bottom of the rear portion of the headgear and the bottom attachment point to the patient interface may change unevenly. Thus, more stretchability at the top or bottom of the headgear may be desirable.

[0837] Although Figure 30 shows a configuration in which the elastic zones have graduated sizes along the width of the band, elastic zones may additionally or alternatively be provided that vary continuously in size along the width of the band, an example of this is shown in Figure 31, where elastic zones 81 and 82 are relatively narrow towards the top of the headgear band and relatively wider towards the bottom.

[0838] The elasticated areas are wider at the bottom so that when loaded in the directions of arrows 801 and 802 the lateral portions of the headgear can be induced to rotate at least somewhat in the directions of arrows 805 and 806.

[0839] The amount of allowable stretch of the headgear can be controlled by varying the size of the stretch zones and the stretch characteristics of the first panel 1 .

[0840] The stretch zones may also be provided in curved configurations, as shown by stretch zones 81 and 82 in FIG.

[0841] Figure 33 shows a further embodiment in which the curved elastic zones face in the opposite direction to that of Figure 33, with elastic zones 81 and 82 curving towards the centre of the headgear.

[0842] In Figure 33, unlike Figure 32, the stretch zones 81 and 82 have larger lateral dimensions toward the center than at their top and bottom ends, so that the intermediate portions of the stretch zones 81 and 82 can be allowed to stretch relatively large amounts.

[0843] While the above examples have shown elastic zones extending vertically across the height of a portion of the headgear to allow for lateral stretching of the headgear, elastic zones may also be positioned laterally across the headgear to allow for vertical stretching of the headgear.

[0844] For example, elastic zones may be provided laterally across the fused zones of the headgear adjacent the lower strap connections, which may allow for more vertical elasticity of the headgear when a load is applied to the connected straps.

[0845] The headgear may include one or more elastic zones, which may bisect the fused portion of the headgear, resulting in multiple separate fused zones, as shown in the configurations of Figures 29-33.

[0846] However, in other configurations, the fused portion of the headgear may be one continuous area, with the elastic zone not bisecting the fused portion of the headgear.

[0847] Regardless of whether the headgear includes one or more elastic zones, the headgear may have one or more continuous fused zones between two or more strap connection portions at a rear portion of the headgear. When a load is transferred between the straps of the headgear during use, the continuous fused zone between the two strap connection portions may facilitate effective transfer of the load through the headgear.

[0848] For example, the rear portion 100 of Figure 14 has a continuous fused region of the first and second panels within the fused zone 41 between the transverse strap connection portions 120a and 120d. In fact, in the configuration of Figure 14, the rear portion 100 defines a continuous region of the fused zone 41 between each of the strap connection portions 120a-d.

[0849] The panels of the headgear may be configured to give the headgear a particular overall shape or configuration that the headgear can assume when not worn. This shape may be created by the existing 3D shape of the panels before they are fused, or by the fusion of the panels, or both.

[0850] Such shapes or structures may be important to inform the patient, or a person fitting the headgear to the patient, of the nature of the various portions and their intended orientation when worn. For example, it may be desirable for the headgear at rest to provide an opening between the straps on each side that can receive the patient's head. Similarly, it may be desirable for the headgear at rest to provide the side straps as separate members that project away from the remainder of the headgear, and potentially independently of each other, to allow easy identification and grasping of each strap by the patient so that it can be connected to a patient interface.

[0851] This shape and configuration may be exhibited, for example, when the headgear 10 is held by a patient, or particularly when a portion of the headgear is gripped by the patient and the remaining portion of the headgear hangs or dangles from the gripped portion.

[0852] Where the headgear or portion of the headgear includes two or more overlapped panels, one or more edges of a panel may extend beyond one or more adjacent edges of the other overlapped panels. An example of this was described above in relation to FIG. 13, where a first panel 1 beyond a second panel 2 is not overlapped and is not supported by the second panel 2. When worn, this configuration may allow contact pressure on the patient's head to be gradually reduced from the edges of the overlapped portion of the first panel 1 and the second panel 1 to the distal most non-overlapping portion of the first panel 1. This may provide an edge softening effect for the patient when the headgear is worn.

[0853] 34 illustrates headgear 10 having such edge-softening properties along at least a portion of the top edge of the rear portion. The rear portion 100 of the headgear 10 includes a first panel 1 and a second panel 2. A portion 1a of the first panel 1 in the rear portion 100 extends beyond the top edge of the second panel 2. The portion 1a of the first panel 1 is not overlapped by the second panel 2. With this configuration, the first panel 1 defines a top edge 401 of the rear portion 100 of the headgear around at least a portion of the back of the patient's head.

[0854] As can be seen in FIG. 34, an upper strap 200 is attached to the rear portion 100 , and portion 1 a of the first panel 1 extends beyond the upper edge of the upper strap 200 as well.

[0855] The overhanging portion 1a of the first panel 1 may provide a softening edge effect for the patient when the headgear is worn.

[0856] 34, the first panel 1 including the overhanging portion 1a is positioned to be on the inside of the upper strap 200 relative to the patient's head. In this manner, the overhanging portion 1a rolls up, preferably over the upper strap 200, away from the patient's head when the headgear is worn.

[0857] The panel having a non-overlapping periphery may be at least one of thinner, softer and less dense than the headgear panel or the portion it overlaps, such as top strap 200 in the case of FIG.

[0858] Although described with respect to forming a pressure grading edge on the upper side of the rear portion 100 of the headgear, the techniques described can be applied to any other portion of the headgear to achieve the same functionality. For example, this panel configuration can be utilized on the lower periphery of the rear portion 100 and / or the ear loops 320.

[0859] The panels of the headgear may be configured to give the headgear a particular overall shape or configuration that the headgear may have when not worn.

[0860] Such shapes or structures may be important to inform the patient, or a person fitting the headgear to a patient, of the nature of the various components and their intended orientation for fitting. For example, it may be desirable for the headgear in an unworn state to show openings between the straps on each side that can receive the patient's head. Similarly, it may be desirable for the headgear in an unworn state to show the side straps as discrete members that project away from the remainder of the headgear, potentially separately from one another, allowing the patient to easily identify and grasp each strap and connect them to the interface.

[0861] This shape and configuration may be exhibited, for example, when the headgear 10 is held by a patient, or particularly when a portion of the headgear is gripped by the patient and the remaining portion of the headgear hangs or dangles from the gripped portion.

[0862] Figure 35 shows headgear 10 that is configured to assume a particular shape and configuration when not worn. The headgear 10 may have an upper strap 200 that is sufficiently stiff to retain at least a partially circular configuration when not worn. This is shown in the example of Figure 35, where the remaining portion of the upper strap 200 that hangs from the patient's hand presents a substantially circular shape.

[0863] Also seen in Figure 35 is the manner in which the straps 300 may project discretely away from and from the remainder of the headgear 10. To provide such a configuration, the panel or panels comprising the straps 300 may be provided from a material having sufficient stiffness to sag with a sufficiently low amount of curvature over their length. Additionally or alternatively, either or both of the rear portion 100 and / or top straps 200 to which the straps 300 are attached may bias the straps to hang outwardly, away from each other and away from the remainder of the headgear 10.

[0864] To achieve such a configuration, the straps 300 and / or the panels of the remainder of the headgear which they overlap may be provided with a natural curl or bend relative to them.

[0865] In some embodiments, the base panel may be overlapped with more peripheral stretch panels that are pre-stretched when fused to the base panel. This may induce a natural curvature in the fused panels to provide the desired natural shape and / or divergence of the straps 300 apart.

[0866] In addition to or instead of any panel configurations for providing the headgear with an unworn configuration to inform the patient of the nature of the different portions or their use or application, the headgear may be configured to inform the patient of these by visual or tactile cues.

[0867] For example, with reference to headgear 10 in FIG. 35, the top straps and rear portion of the headgear may be provided in one color or primarily in one color. One or more of the straps 300 may be provided with a different color and / or texture than that of the top straps 200 so as to be easily distinguished from the remainder of the headgear. As seen in FIG. 35, top straps 301 and 303 may be provided with a different color and / or texture than that of the bottom straps 302 and 304. Any such structural, visual and / or tactile cues that may be incorporated into the headgear may additionally or alternatively be utilized to encourage the patient to distinguish between the inner surface 5 and the outer surface 4 of the headgear 10.

[0868] For example, some or all of the panels making up the inner surface may be provided having a different colour or different colours than some or all of the panels making up the outer surface 4 of the headgear.

[0869] In other configurations, some or all of the panels making up the inner surface 5 of the headgear may have a different texture than some or all of the panels making up the outer surface 4. In particular, the texture of the inner surface 5 may be softer in part or in whole than the outer surface 4 to help inform the patient that this part should be closer to the head, as well as to enhance comfort when worn.

[0870] As seen in Figures 36A and 36B, the location of the junctions 572 between the rear portion 100, the top straps 200 and the side straps 300 can be configured to rest over the patient's ears.

[0871] The side straps 300 of the headgear 10 may include one or more strap panels that are fused together.

[0872] The ends of the side straps of the headgear may pass through fasteners on the respiratory interface and fold back on themselves to fasten. To allow this, there may be a two-part fastener system on the side straps, such as a hook and loop fastener.

[0873] However, when folding the side straps over themselves and tightening them, it may be desirable to provide some form of feedback to the patient as to how tight the mask is and / or to provide some regular steps in which the straps may be adjusted to help easily equalize the amount the different straps are tightened.

[0874] 37A shows an index panel 335 that is fused to the base panel 310 to form side straps. The index panel 335 includes at least a series of stepped features 337 that extend at least partially between the two sides of the index panel 335.

[0875] The index panel 335 may comprise a material that is relatively stronger, stiffer, denser, and / or more rigid than the underlying base panel 310 to which it is fused.

[0876] FIG. 37B shows the index panel 335 of FIG. 37A fused to the base panel 310.

[0877] By providing an index panel 335 on the outer surface 15 of the headgear relative to the base panel 310, when the strap ends are threaded through the fasteners of the respiratory interface and pulled back towards the rear portion 100 of the headgear, the index panel 335 can contact the fasteners of the respiratory interface.

[0878] When there is tension on either side of the strap 301 across the respiratory mask fastener, the stepped feature 337 of the index panel 335 may provide tactile feedback to the patient as the strap tightens on the respiratory interface.

[0879] An additional function of such an index panel 335, being of a relatively stronger, stiffer, denser and / or harder material than the base panel 310, may be to provide abrasion resistance to the strap 301 as it engages and passes over the fasteners of the respiratory interface. For this purpose alone, the strap may include an index panel 335 without a defined cut-out 336 for providing tactile feedback, but may instead have an index panel 335 without a cut-out.

[0880] FIG. 38 shows a further configuration of a side strap 301 that includes a base panel 310 and an index panel 335 fused thereto.

[0881] 38, the distal portion of the strap 301 has a first portion 331 of a fastening system that corresponds to a second portion 332 of the fastening system within a cutout in the index panel 335. The second portion 332 may be provided by the material of the base panel 310 itself or by another material fused thereto.

[0882] 37A-37B and 38 as including a unitary panel having a plurality of cutouts 336 to define step features 337, according to other embodiments, index panel 335 may be provided identically to step features 337. In other words, index panel 335 may instead include a plurality of step features 337 without any connecting material to define a single unitary panel.

[0883] The step features 337 may present a raised surface above the surface of the underlying strap panel such that the step features provide resistance to movement of the straps relative to the interface. The spacing of the step features may provide an indication of the indexing of each strap by the patient as they adjust the tension of the headgear straps.

[0884] To provide the indexed resistance, the step feature 337 may be of a different, potentially harder or denser, material than the material of the underlying strap panel.

[0885] An example of such a strap end feature 350 is shown in Figures 39A and 39B. As seen in Figure 39A, the strap end feature 350 includes a first tab panel 351 that at least partially overlaps the strap panel 310. As seen in Figure 39A, the first tab panel 351 has a greater surface smoothness than that of the strap panel 310 and therefore may be distinguishable from it by touch.

[0886] On top of the first tab panel 351 is a first portion 331 of a hook and loop fastener. In some embodiments, the outer surface of the strap panel 310 may form a second portion 332 of the hook and loop fastener for engaging the strap end with the strap when the strap end is folded back onto itself.

[0887] 39A , the strap panel 310 includes a second half 332 of a hook and loop fastener. For example, the strap panel 310 can be a solid loop material, and a loop provided on a surface of the strap panel 310 can be utilized as the loop of the hook and loop fastener.

[0888] The strap panel 310 may be overlapped solely by a first tab panel 351 or, as shown in side view in FIG. 39B, may be overlapped on its other major surface by a corresponding second tab panel 352.

[0889] While the presence of the first and / or second tab panels 351 and 352 may provide a desired degree of ability to distinguish the strap end from the remainder of the strap, adhesive may be utilized to enhance this distinction. For example, adhesive may provide the strap end feature 350 with increased stiffness compared to the strap panel 310. This stiffness difference may act as an additional or additional physical cue to the patient as to the presence of the strap end.

[0890] The first and second tab panels 351 and 352 may be fully overlapped against the strap panel 310 to provide a three-panel stack, such as that shown by the first overlap region 21 in FIG. 39B.

[0891] In other configurations, the tab panels 351 and 352 may extend distally to the ends of the strap panel 310 to form the second overlap region 22, as seen in FIG. 39B.

[0892] The difference in thickness between the first overlap region 21 and the second overlap region 22 may provide an additional tactile cue to the patient as to the location of the ends of the strap.

[0893] If the tab panels 351 and 352 include a second overlap region 22 that only overlaps one another alone, rather than overlapping both sides of the strap panel 310, an additional amount or a different type of adhesive may be utilized in the second overlap region 22. This may provide the second overlap region 22 with increased stiffness compared to the stiffness of either the first overlap region 21 or the strap panel 310 itself, which may provide another potential form of cue for the patient to grasp the tab ends.

[0894] 41 shows an overlapping view of the tops of two different configurations of headgear 10a, 10b, each having a different configuration of the top straps 200.

[0895] The first configuration 10a has an upper strap 200a, and the second configuration 10b has an upper strap 200b. The upper strap 200b is oriented so that it does not project laterally outwardly beyond the upper strap 200a, but instead extends primarily upwardly. In FIG. 41, the upper strap 200a is oriented to be a substantially continuous extension of the adjacent portion of the rear portion 100.

[0896] As seen in Fig. 41, upper straps 200a extend laterally outward at an angle of approximately 35 degrees relative to the horizontal. A second configuration having upper straps 200b protrudes relative to the horizontal at a steeper angle of approximately 70 degrees relative to the horizontal.

[0897] The angle of the headgear top straps 200 relative to the lateral axis of the headgear may affect where the top straps lie on the patient's head in use. In some configurations, it may be desirable for the top straps to pass vertically and laterally over the patient's head in use, with minimal or no proximal or distal displacement between the base and end of the top straps.

[0898] To improve comfort, it may be desirable to select the angle of the upper straps relative to the lateral axis of the headgear so that the upper straps lie flat against the patient's head regardless of where the straps pass over the patient's head.

[0899] In use, the more steeply oriented upper strap 200b of FIG. 41 crosses further forward across the patient's head than the more shallowly oriented upper strap 200a.

[0900] Manufacturing of headgear according to the present disclosure may involve fusing some or all of the headgear. Although various separate welding processes have been described elsewhere herein, such as by a welding press of Figures 9A and 9B, welding may additionally or alternatively be provided as a continuous process.

[0901] For example, Figure 42 shows a continuous welding operation in which two rollers 510 are used to continuously weld together two panels 511 and 512. Such a process may be desirable to increase production speed and may be particularly suitable for continuous shapes such as welding lengths of panels that can then be cut up for use as headgear straps.

[0902] A continuous welding process may also be used to form one or more folded edges of headgear, for example, as described in more detail below in connection with Figures 63-67. One example of a continuous welding operation to form a headgear portion having folded edges is shown in Figure 42, where a roller 510 is used to continuously weld a first panel 511 and a second panel 512 along an edge of the first panel 511, such that each of the edges of the first panel 511 is folded over the second panel 512.

[0903] The continuous welding process may be applied to one or more panels of continuous width, although the width of the panels may vary.

[0904] While Figure 42 shows a continuous welding process taking place in a plane, the continuous welding operation can be performed in other configurations, such as where one or more panels are rolled concentrically and the helical joints are welded, etc. An example of this is shown in Figure 43, where a panel 511 is rolled into a tubular shape and a roller 510 welds at least the overlapping portions to fuse them together and hold the panel 511 in the tubular shape.

[0905] Headgear according to the present disclosure may be fused using one or more different fusion methods. For example, fusion may be provided by one or both of a discrete process and a continuous process. Fusion may be applied using only one type of fusion process, such as radio frequency welding, or multiple different processes, such as both radio frequency welding and direct thermal welding, may be applied to the same or different portions of the headgear.

[0906] The continuous welding process may also be used to define welded and unwelded zones or vary the degree of welding of the panels between the rollers by using debossed areas of the welding rollers in a configuration similar to that described in connection with the die of FIG.

[0907] FIG. 44 is an example of a continuous welding process in which two rollers 510 each include a pattern of debossed areas 513 so that, when welded, a panel 511 is provided with a corresponding pattern of unfused areas 514. The panel or panels to be fused are pre-stretched before fusing. Pre-stretching in combination with fusing can be used to give a flat panel a three-dimensional shape. For example, a panel can be stretched and then only a portion of it can be fused. When tension is released, the fused portion can regain a smaller amount of stretch than the unfused portion. This can encourage the panel to assume a 3D shape.

[0908] Pre-stretching can be utilized in discrete or continuous fusion processes. Figure 45 shows a continuous welding process with two rollers 510 each acting as a welding die to weld one or more panels 511, which are pre-stretched by a set of secondary rollers 515.

[0909] A pre-stretched panel or set of panels may be stacked with another panel or set of panels that is not pre-stretched, and the stacked panels may then be welded together. Pre-stretching on one side of a stacked set of panels may be utilized to distort the panels into a desired 3D shape.

[0910] In accordance with various configurations, it may be desirable to form a pocket or void between two panels that are welded together. Such a pocket or void may be formed by selectively unwelding the overlap area where the void is desired.

[0911] If additional volume is desired in the pocket or void and / or if it is desired that the panel have fused material properties such as surface finish or stiffness in the pocket or void, one or more inserts 520 may be used in forming the pocket or void.

[0912] Figure 46-1A shows two inserts 520 provided on a first panel 511. The inserts 520 shown have a rectangular cubic shape, but it will be understood that they can be any desired shape as needed to impart a desired shape to a pocket or void.

[0913] In FIG. 46-1B, the second panel 512 is laid over the first panel 511 and the two panels are fused together, after which the insert 520 is removed from the open, unfused side 521.

[0914] A second panel may optionally be stretched over the insert 520 before the panels are fused.

[0915] As can be seen in FIG. 46-1B, the fused second panel 512 retains a 3D shape to define two pockets 521.

[0916] Once the insert 520 is removed, the unfused side 521 may then be fused or otherwise closed, if desired, to close the pockets and form them into closed interior cavities within the panel.

[0917] If fusion is applied to the entire insert 520, they may be made of a non-fusible material. For example, in the case of high frequency welding, they may not include bipolar materials. Instead, in the case of direct heat welding, they may have a melting point higher than the welding temperature.

[0918] FIG. 46-2 shows a first panel 1 partially overlapped by a second panel 2. The overlap region 21 is fused leaving a series of gaps 530 inside the overlap region 21 where the first panel 1 and the second panel 2 are not fused to one another.

[0919] FIG. 46-3 shows an alternative configuration in which a first panel 1 and a second panel 2 are fused to one another along two opposing faces, but leaving a continuous pocket 530 extending along the length of the two overlapping panels.

[0920] According to some embodiments of the present disclosure, fused panels of the headgear may be used to define the air conduits. One example of such a configuration is shown in FIG. 47A, where the headgear 10 defines an air conduit 522 in each of its two side arms or side straps 301 and 302. The front of each side arm is connected to a patient interface 600. The external conduits 601 and 602 may be attached to a more posterior portion of the headgear at the rear of each of the straps 301 and 302, as seen in FIG. 47A. In other configurations, the headgear air conduits may extend into the rear portion or top straps of the headgear, and one or more external conduits may be attached to one or more locations of the rear portion or top straps of the headgear.

[0921] By selectively leaving portions of the headgear unfused, air conduits may be formed in the headgear. Figure 47B shows a cross-sectional view through line AA in Figure 47A. In Figure 47B, the first panel 511 and the second panel 512 are fused together along their edges 821 and 822, but a central portion is left unfused to define the air conduit 522.

[0922] In addition to being left unfused, the air conduits may be formed using an insert, such as insert 520 described in connection with Figures 46-1A and 46-1B.

[0923] A pocket in an unfused zone of the headgear may be accessible through the unfused peripheral edges of the overlapped panels, as shown in Figure 46B. The pocket may also be accessible through a cut-out in one of the overlapped panels if the peripheral edges of the overlapped panels are completely fused together.

[0924] The pockets in the headgear may be used to receive and hold inserts, such as reinforcing inserts.

[0925] The pockets may be further utilized in the manufacture of the headgear if the headgear is assembled in multiple steps. For example, Figures 48A-48D are steps in a process for attaching straps to the remainder of the headgear by inserting the straps into pockets in the headgear.

[0926] 48A shows a portion of the rear portion 100 of the headgear 10, including the strap connection portion 120. The rear portion 100 has a first panel 1 and a second panel 2 that partially overlaps the first panel 1. The second panel 2 includes a cutout 530. In FIG. 48A, the first panel 1 is visible through the cutout 530 in the second panel 2.

[0927] The overlapping first and second panels are then welded together around their periphery as shown by fused zone 41 in Figure 48B. The fusion around the periphery forms a pocket 531 between the first and second panels, which is accessible through cutout 530.

[0928] With the first and second panels joined together, the ends of the straps 300 are inserted through the cutouts 530 and into the pockets 531, as shown in 48C.

[0929] The strap ends can be the same size as the rest of the strap, or as shown in FIG. 48C, the strap ends can be a reduced size.

[0930] With the strap ends inserted into the pockets 531, the pockets and strap ends can be fused to secure the straps to the first and second panels. Figure 48D shows the arrangement after the parts have been fused over a portion of the pocket to define the fused zone 42.

[0931] By assembling the straps to other panels of the headgear by inserting one part into the pocket of the other, the possibility of parts shifting during assembly can be limited. For example, as in Figures 48A-48D, only the end portions of the straps 300 are sized to be received through the notches 530. Using pockets to provide such physical constraints can simplify manufacturing compared to other methods, such as joining a strap or other panel by sandwiching it between the loose ends of two other panels.

[0932] In an alternative configuration, the strap and rear portion can be joined as shown in Figures 48A-48D, but in a second step can be joined without the cutout 530 in the second panel 2 by leaving the strap adjacent peripheral portions of the first panel 1 and second panel 2 unwelded. The strap 300 can then be inserted into the pocket 531 through the open peripheral portion and the components can then be welded together.

[0933] As previously mentioned, selective fusing of different regions of a panel or multiple overlapping panels may be employed to impart desired properties to the headgear or portion of the headgear. These properties may include surface properties such as texture, thickness, stretch properties, or UBL properties.

[0934] Such selective fusing may be performed on a region by region basis, where entire portions of the headgear may be fused and other portions may be left unfused. For example, the entire overlap region 21 may be fused while the entire non-overlapping region 32 may be left unfused, as in Fig. 14. Alternatively, the perimeter or a portion of the overlap region may be fused and the non-overlapping region and interior portions of the overlap region may be left unfused, as in Figs. 48B-48D.

[0935] Selective fusing may additionally or alternatively be performed to provide patterns of fused or unfused regions, such as those described in connection with Figures 21 and 19, respectively.

[0936] As mentioned above, according to some configurations, the headgear may meet the straight line test at one or more locations such that along a straight line drawn between two edges of the headgear, more particularly between two edges of an overlap region of the headgear, the welded length is greater than the unwelded length.

[0937] FIG. 14 shows a rear portion 100 of the headgear that satisfies the straight line condition along any straight line drawn between the two edges of the overlap region 21.

[0938] Although the overlap region 21 of the rear portion 100 in Figure 14 is completely fused, the straight line test may be satisfied in other configurations where the overlap region is not completely fused. For example, in the configuration of Figure 19, the size and spacing of the fused zones 53 may be positioned such that the straight line condition may be satisfied along one or more lines drawn between locations along the top and bottom edges of the overlap regions of the first and second panels.

[0939] FIG. 49A is a diagram of an exemplary panel 1, and FIGS. 49B-49D show examples of different arrangements or patterns of fusion that may be provided on one or more panels of the size of exemplary panel 1.

[0940] FIG. 49B shows an array of spaced apart circular fused zones 41 within the unfused peripheral region 31.

[0941] FIG. 49C shows the same arrangement of fused zones 41 as in FIG. 49B, but the fused zones are smaller and more densely packed than in the configuration of FIG. 49B.

[0942] The fused configuration of Figures 49B and 49C may reduce stretching of the panels thus fused, however the stretch properties in each direction of arrows 808 and 809 in Figures 49B and 49C will vary to the same extent due to the symmetrical placement of the fused zones in each direction.

[0943] However, in some configurations it may be desirable to provide directionally-varying stretch properties by selective fusing.

[0944] 49D illustrates another pattern in which fusion may be applied, where the density of fused areas decreases in rows along the panel. Such a configuration may provide uniform stretch properties in the direction of arrow 808 throughout the panel when the panel is stretched in the direction of arrow 809, but may provide non-uniform stretch properties in the direction of arrow 809 when the panel is stretched in the direction of arrow 808. As the panel is stretched in the direction of arrow 808, the density of fused areas along the stretch direction decreases, resulting in a greater degree of stretchability down the panel.

[0945] Such an arrangement may therefore provide localized control of the directional stretch properties of a single panel or composite of panels, which may allow stretch to be provided to only the desired areas, in the desired directions, and to the desired extent.

[0946] By selectively fusing the headgear, the properties of the panels or regions of overlapping panels can be altered without adding other materials or fasteners, which may allow headgear with highly customized localized properties to be manufactured from a single panel of a single property or from a stacked combination of multiple panels, each of a single property.

[0947] 50 shows a headgear strap 300. The strap has a fused zone 41 that defines a bifurcated region where the strap splits into two portions 300a and 300b. The bifurcated nature of the fused zone 41 allows the strap portions 300a and 300b to spread apart from one another in the direction of arrows 811, while the fused zone continuing from the bifurcation of the strap towards its end 300c along the direction of arrow 812 resists or prevents stretching in that direction.

[0948] Figure 51 shows another similar configuration, but where the strap 300 defines a first fused zone 41 toward the strap end 300c and is then fused to decrease the amount of fused area toward the bifurcation of the strap and along each portion 300a and 300b. This configuration provides similar functionality as described in connection with Figure 50, but the strap has an increased amount of stretch in the direction of arrow 812 in the region proximate the bifurcation due to the discontinuity of the fused zone 42 in that region along the direction of arrow 812.

[0949] Although described with respect to straps, it will be understood that the same concepts described with respect to Figures 50 and 51 can be applied to other portions of headgear.

[0950] For example, Figure 52 shows the rear portion 100 of the headgear 10 and adjacent portions of the two straps 301 and 302. The rear portion 100 and straps 301 and 302 may be formed from a single panel or a combination of panels. As seen in Figure 52, the rear portion 100 and straps 301 and 302 are fused such that the straps are fused along their lengths and that fingers of the fused regions define fused zones 41 and 42 that extend from each strap 301 and 302 into the rear portion. The size of each fused finger tapers toward its tip.

[0951] Such a configuration may allow stretching in the middle of the rear portion while gradually restricting stretching of the rear portion 100 laterally in the direction of arrow 812. However, the fused fingers may not significantly affect stretching of the rear portion in the direction of arrow 812 because the unfused material between the fingers allows stretching in that direction.

[0952] 53 shows a rear portion 100 having a fused zone 41 that extends continuously from one lateral side of the band 110 to the other, and a fused zone 42 that extends in a continuous line from the strap connection portion 120 to the central portion of the band 110. Such a configuration may increase stiffness and load transfer capability along the direction of the continuation of the fused zones 41 and 42, but still allow for vertical stretch. For example, the headgear may resist stretching along the lateral direction of the band 110 more than along the height of the band.

[0953] 54 shows another headgear 10 when worn by a patient. The headgear 10 has a rear portion 100 with a fused zone 41. The fused zone 41 includes a continuous portion toward the top of the rear portion and then three triangular portions that each taper toward the bottom of the rear portion.

[0954] Due to the configuration of the fused zones 41 , the headgear 10 may limit lateral stretch towards the top of the rear portion, but gradually allow stretch towards the bottom of the rear portion 100 .

[0955] 55A, 55B, and 55C show further examples of how selective fusing of panels can provide directionally distinct stretch properties.

[0956] As can be seen in Figure 55A, panel 1 is fused to define two fused zones 41 and 42. In the example of Figure 55A, the two fused zones are mirror image "T" shapes.

[0957] The fused zones define a continuous fused portion of the panel along a first diagonal of the panel in the direction of arrow 813, but have a gap of unfused panel between the two fused zones 41 and 42 along the other diagonal in the direction of arrow 814.

[0958] Although shown with a "T" shaped fused zone, it will be understood that directional stiffness in the first lateral direction 813 relative to the second lateral direction 814 may be provided by two parallel adjacent portions of the "T" extending in direction 813 without a leg extending in direction 814.

[0959] 55A-C, each "T" shaped portion extending in the direction of arrow 814 may provide in-plane distortion of the panel when stretched along the diagonal of arrow 814. As seen in FIG. 55C, the arms of the "T" shaped portion extending in direction 813 may bend toward each other when stretched along arrow 814.

[0960] Although directionally differing stretch properties are shown in Figures 55A-C using a mirrored "T" shaped fused zone, it will be understood that the fused zones may be shaped and oriented to provide desired directional stretch properties or produce other desired in-plane deformations under stretch.

[0961] It is a known problem that some full face masks may have a tendency to move upward on the patient's face when worn. By using panels with directionally different stretch properties, straps can be produced that are resistant to stretch in the direction of movement. Such a configuration can help prevent movement of the mask on the patient's face while still maintaining stretch in other directions that may be desired. For example, by employing selective welding to provide directionally different stretch properties, headgear straps can be produced that have reduced stretch across their length but not along their length.

[0962] It will further be appreciated that by controlling the orientation of fused zones, such as the "T" shaped fused zones 41 and 42 in the configuration of Figures 55A-C, it may be possible to locally reorient the stretch and non-stretch directions of portions of headgear. For example, different portions of the headgear straps may permit or resist stretch in different directions.

[0963] Although Figures 55A-C show the use of only two fused zones, it will be understood that a similar pattern of small fused zones may be utilized over a larger area of ​​one or more panels.

[0964] Pre-stretching of the panels may be combined with fusing to create surface features in the headgear.

[0965] An example of such a configuration is shown in Figures 56A and 56B. In Figure 56A, panel 1 is shown pre-stretched in the direction of arrow 815 before being fused to define the pattern of fused zones 41-44. After fusion, the stretch is removed and the panel contracts in the direction of arrow 816. As the fused portions move towards each other, they may cause the unfused portions of the panel to bunch up. This is shown in Figure 56B where the panel recovers in the direction of arrow 816 to form panel bunching 540.

[0966] While fusing panels can be used to change material properties such as stretch properties, to change surface properties, or to form surface features such as clusters 540, fusing can also be used to provide structure to the headgear.

[0967] As the degree of fusing increases, the fusing panel(s) can become more plasticized and more rigid, and thus fusing the panel(s) can be used to provide structure to the headgear.

[0968] Such additional structure provided by the fused zones may allow for a reduction in headgear size and bulk.

[0969] Structure may be provided to the headgear by fusing panels or by fusing another element, such as a solid piece of plastic, to one or more panels of the headgear.

[0970] 57 shows headgear 10 holding interface 600 on the face of a patient 700. Headgear 10 has three separate fused structures 45-47. Each fused structure is relatively stiffer than the surrounding headgear and serves to transfer loads between different portions of the headgear while maintaining the desired shape of the headgear.

[0971] A first fused structure 45 provides rigidity between the rear portion 100 and the upper strap 200. A second fused structure 46 provides rigidity between the upper strap 200 and the upper side strap 301. A third fused structure 47 provides rigidity between the rear portion 100 and the lower side strap 302.

[0972] The first fused structure 45 may help prevent upward or downward movement of the rear portion 100 on the patient's head. Similarly, the second fused structure 46 and the third fused structure 47 may each resist upward or downward movement of the straps, which in turn prevents upward or downward movement of the interface 600 on the patient's face.

[0973] Although shown as three separate structures in FIG. 57, in other configurations the three fused structures 45-47 may be provided as a single continuous structure.

[0974] The structure provided to the headgear by such fused structures may allow for different configurations of the shape and position of the headgear on the patient's head. For example, they may allow the rear portion to be positioned further away from the patient's neck and higher on the patient's head than would normally be possible without causing distortion of the headgear.

[0975] Figure 58 shows an embodiment of headgear 10 for holding a nasal interface 600 on a patient's face, the headgear being configured so that the rear portion 100 rests higher on the back of the patient's head than the headgear 10 of Figure 57.

[0976] Due to the elevated position of the rear portion 100, the lower side straps 302 must extend below and around the patient's ears to avoid interference with the patient's ears. The first fused structure 48 provides rigidity to the rear portion 100 and the lower side straps 302 around behind the patient's ears. Similarly, since the upper side straps 301 do not directly connect to the rear portion 100, the second fused structure 49 provides rigidity between these two portions.

[0977] In addition to or instead of allowing the rear portion 100 to be repositioned further up on the back of the patient's head, as shown in Fig. 58, the use of fused structures may allow the headgear to be reconfigured to be positioned further away from the patient's ears or portions of their ears. This may allow the headgear to fit a wider range of people without interfering with the ears, and may increase comfort as the patient can adjust the headgear to a wider range of positions without contacting the ears.

[0978] As can be seen in FIG. 58, the headgear is shaped to provide extra clearance from the patient's ears than the headgear of FIG. 57, particularly in the areas above and behind the patient's ears.

[0979] The use of fused structures may reduce the number of straps used to connect the headgear 10 to the patient interface 600. For example, FIG. 59 shows a side view of headgear 10 connecting to the interface 600 at a single point. Although the headgear may include pieces located on either side of the patient's head, the use of a rigid fused structure 45 may facilitate only a single point connection between the headgear 10 and the interface 600.

[0980] Such fused structures 45 may be formed by highly fused panels, in particular textile or fabric panels, or they may additionally or alternatively be formed by rigid materials fused to one or more substrate panels.

[0981] In addition to being used to process or join panels together to form headgear, fusion may be used to join other fasteners to the headgear. This includes cases where the fused structure is provided by a rigid material that is fused to one or more backing panels. It may also include cases where attachment fasteners such as clips, buckles, or hook and loop pads are included as part of the headgear.

[0982] 60A shows a side view of headgear 10 with rear portion 100 and single straps 301 and 302 on either side of the headgear. The headgear 10 is connected to interface 600. Fasteners 550 are fused to a panel of rear portion 100.

[0983] The fastener 550 includes a slot through which the side strap can pass so as to be folded back on itself and secured.

[0984] Figure 60B shows a partial cross-sectional view through line AA of Figure 60A, illustrating the fastener 550 and the slots for threading the straps. The rear portion 100 of the headgear at the fastener 550 includes a first panel 1 and a second panel 2 overlapping and secured to either side of the fastener 550.

[0985] The fastening of such fasteners may be by fusing. The fusing process may be the same or different than that used for fusing the headgear panels. The fasteners may be fastened simultaneously with the fusing of the headgear panels or may be fastened in a separate step.

[0986] For example, if the headgear panels are fused by radio frequency welding, then fastener 550 of Figures 60A-60B may be a bipolar material and fused to the first and second panels 2 in the same radio frequency welding step in which the panels are fused to each other. Fastener 550 may alternatively be fused to panels 1 and 2 in a subsequent radio frequency welding step.

[0987] 61A shows a portion of the headgear, strap 300, with fastener 550 fused thereto. Panels 1 and 2 of strap 300 overlie and overlap fastener 550 and are fused thereto to provide a seamless transition between the strap and the fastener.

[0988] As shown in Fig. 61B, which shows the arrangement of Fig. 61A before panels 1 and 2 are fused to fastener 550, fastener 550 is formed with recesses 55 corresponding to the shape of the ends of panels 1 and 2. The height of fastener 550 also tapers towards the straps. These features can help provide a seamless transition between the straps and the fastener.

[0989] FIG. 62 shows an example of another form of fastener 550 that provides a slot rather than the hook feature shown in the fastener of FIGS. 61A and 61B.

[0990] Although generally described as being connected by fusion bonding, in other configurations the fasteners may be attached to the headgear panels by other methods such as adhesives or stitching.

[0991] The fasteners as separate pieces may be attached to one or more panels of the headgear by fusing, as shown and described in connection with Figures 61A-61B and 62, although the fasteners may additionally or alternatively be provided to the headgear by other methods.

[0992] After the panel or panels are formed into the desired shape, they may be fused to form that portion of the panel into solid plastic. For example, the ends of the panel or panels may be rolled to form the shape of clip fastener 550 in FIG. 61A and then fused to solidify the panel or panels into that shape.

[0993] The panel or panels themselves may be fused to form the fixture, or alternatively, the fused portions may be used to form a substrate for overmolding, which then forms the desired fixture.

[0994] For example, the ends of one or more panels can be fused together to create a section that is rigid enough to allow for overmolding. In such a configuration, the ends of the one or more panels can be formed into the shape or part of the final fixture, or can be fused together in a flat configuration.

[0995] Once the fusion bonds have provided sufficient structural integrity, one or more panel ends can be inserted into a mold and overmolded with another material, such as a solid plastic material.

[0996] It may be desirable for the edges of the headgear or the edges of the individual panels to be smooth and soft to maximize patient comfort. If the edges of the headgear are defined by cut edges of the panels, the edges may require treatment, such as fusing, to prevent unraveling, unless the panels are made of a material that is resistant to unraveling. Such treatment may harden or stiffen the edges, reducing comfort. Even if the edges are defined by a material that is resistant to unraveling, it may be desirable to further soften or smooth the edges.

[0997] One way of treating the edges of the headgear, or of an individual panel, is to fold another panel around it so that the periphery of the headgear or panel is no longer defined by a cut edge, but by the continuous rolled surface of the panel.

[0998] Figure 63 shows a first panel 1 with a second panel 2 folded over one of its edges. The panels may then be fused together only away from the folded edge or over the entirety of panels 1 and 2.

[0999] FIG. 64 shows another configuration of a first panel 1 with a second panel 2 folded over around one edge thereof. In the configuration of FIG. 64, the folded panel is not strongly folded over on itself, but instead defines a void 530 at the edge. Such a void may be formed by using a sufficiently rigid panel for the second panel 2 that it is not folded completely over on itself. The void may also be formed by the temporary or permanent use of an insert that is placed at the edge and around which the second panel 2 is folded.

[1000] Figure 65 shows another configuration of a first panel 1 having a second panel 2 folded over around both of its lateral edges. In Figure 65, the second panel 2 also defines gaps 535 and 536 at each of the folded over edges.

[1001] Figure 66 shows the configuration of Figure 65, but with voids 535 and 536 filled with respective edge members 532 and 533. The edge members 532 and 533 can be provided at the edges of the first panel 1 when the second panel 2 is wrapped around the first panel 1, or if the voids are formed without the need for an insert, the edge members 532 and 533 can be inserted into the voids 535 and 536 after the second panel 2 is wrapped around the first panel 1 and they are fused together.

[1002] The edge member may serve to hold the gap open. The edge member may additionally or alternatively provide structure to the edge, such as shape memory. For example, if a metal filament is used as the edge member, it may be deformable but help hold the edge in a set shape. Further examples of edge members may include beads or rope piping.

[1003] 67 shows another second panel 2 wrapped around both edges of the first panel 1, but leaving one face of the first panel 1 substantially exposed. The first and second panels can then be fused at arrow 817. Such a configuration may be desirable when surface properties of the first panel, such as UBL properties, are utilized, but the edges of the panel are softened or rounded.

[1004] 68A shows headgear 10 according to one embodiment. The headgear 10 is attached to an interface 600. The headgear has two straps 301 and 302 and a rear portion 100. The headgear is formed from a number of overlapping and fused panels, with at least a portion of the edges of the headgear being defined by folded panels rather than cut edges.

[1005] Figure 68B shows a cross section through line AA of Figure 68A. In cross section, the headgear strap 301 has a first panel 1 surrounded by a wider second panel 2 that is folded back around the first panel. The folded edges are each approximately the same width as the first panel 1, so that the assembly of the first and second panels is approximately three times the width of the first panel 1 in total.

[1006] Each of the folded edges defines a gap 535 and 536 through which the second panel 2 is folded back onto itself.

[1007] The use of inserts or piping around which the panels are folded and welded can be utilized to define other features in addition to the edges of the headgear. For example, as seen in FIG. 69A, a first panel 1 can be folded around a bead 534 and then fused to itself adjacent the bead 534 at the location of arrow 818. The free end of the first panel 1 can then be folded outward in the direction of arrow 819 to the configuration shown in FIG. 69B. In this configuration, the bead and the wrapped second panel can define a slider along which an adjustable fastener, such as a hook or buckle, can slide.

[1008] If a fold is provided to the assembly rather than a cut end, the assembly of FIG. 69B may be further encased by a second panel 2, as shown in FIG. 69C.

[1009] Fusion can be deployed to form other types of adjustment mechanisms. For example, Figure 70A shows a panel or stack of panels fused to form an array of rigid plasticized buttons 551. Buttons 551 are localized protuberances on the panel or stack of panels that can mate with another panel or fastener that has a corresponding array of holes through which buttons 551 can mate, in the same manner as the snap-fit ​​adjustments on a baseball cap.

[1010] FIG. 70B shows a cross section along an array of buttons 551 in FIG. 70A, illustrating how one or more panels can be fused into a rigid ridge.

[1011] 71 shows another form of adjustment feature where a panel or stack of panels are fused together to form an array of teeth 552. The teeth 552 can be used to provide a one-way adjustment mechanism in the nature of a zip tie.

[1012] The adjustment features may be formed by fusion bonding, which causes the material to melt and sag to form the buttons. They may also be formed using a die having protrusions and depressions that correspond to the desired shape of the adjustment features, such as dies 503 and 504 in Figures 9A and 9B.

[1013] Additional materials may be added between the panels of the headgear before the panels are fused together. These materials may be fusible or non-fusible. For example, inserts that form voids or pockets may be placed between the panels, or beads or filaments that form edges may be placed between the panels or within the folds of one of the panels.

[1014] FIG. 72A illustrates an exemplary embodiment of headgear 10 attached to an interface 600.

[1015] Figure 72B is a cross-sectional view through headgear 10 at line AA in Figure 72A. In this cross-section, headgear 10 has a first panel 1 partially overlapped by a second panel 2. Peripheral portions of the overlapped panels are fused to define a first fused zone 41 and a second fused zone 42. Filaments 560 are disposed within a non-fused zone 51 between the two overlapped panels and between the two fused zones 41 and 42.

[1016] The filaments 560 may provide additional structure to the headgear, such as providing shape memory if the filaments are a plastically deformable metal.

[1017] In another embodiment, such filaments 560 may be used to provide fit adjustment to the headgear, as described below.

[1018] The filament 560 may be interposed and positioned between the two panels prior to fusing in a discrete fusing process. In another configuration, as shown in Figure 72C, the filament 560 may be positioned between the first panel 1 and the second panel 2 as part of a continuous fusing process.

[1019] FIG. 72D is another view of a fused first panel 1 and second panel 2 with a filament 560 provided in a pocket defined by a zone where the two panels are not fused to one another.

[1020] 73 is a partial view of headgear 10 in which filaments 560 are provided on each of the side straps 301 and 302 that extend along the top strap 200. After either the side strap end or the top strap end of filament 560 is secured, the other end can be pulled to adjust the fit of the headgear in the same manner as a drawstring.

[1021] As shown in FIG. 73, the headgear 10 may include a fastener 550 through which the filament 560 passes to allow fixed adjustment of the tension of the filament 560.

[1022] According to the present disclosure, the headgear may include a rear portion and two or more straps for connecting between the rear portion and the patient interface. Some or all of the straps of the headgear may be integrally formed with the headgear by being formed from one or more of the same overlapping panels as the rear portion of the headgear. In other configurations, one or more of the straps may be formed separately and attached to the rear portion of the headgear. As previously discussed, FIG. 11 illustrates a configuration in which separate straps 200 and 301-304 are attached to the rear portion 100 to form the headgear 10.

[1023] The strap or straps of the headgear may have either a linear or non-linear shape when laid flat. Using a strap that has a linear shape when laid flat may improve yields of the material or materials from which the straps are formed.

[1024] The headgear straps may be made from a single panel, or, such as the rear portion, from multiple overlapping panels. Alternatively, one or more of the headgear straps may be a laminate of another material or materials, such as foam and fabric.

[1025] Straps that are formed separately from the rear portion of the headgear may be attached to the rear portion by one or more different methods. In at least some configurations, one or more of the headgear straps may be fused to the rear portion. The fusion may be performed by welding, such as ultrasonic welding.

[1026] In other configurations, the strap or straps may additionally or alternatively be attached to the rear portion by other methods, such as by gluing or stitching.

[1027] Instead of being permanently attached, some straps may be removably attached to the rear portion of the headgear. This may facilitate, for example, replacing worn straps or changing the type or size of straps used with a particular rear portion. One or more straps may be removably attachable to the rear portion, for example, by fasteners or clips or a hook-and-loop arrangement.

[1028] Where attachment of the strap(s) includes welding the strap(s) to the rear portion, one side of the strap(s) may be welded to one or more panels in the rear portion. For example, in the configuration of Figure 11, straps 200 and 301-304 are laid over the overlapping first and second panels 1 and 2, respectively, and attached thereto by only one side of each strap.

[1029] In other configurations, the straps may be at least partially sandwiched between two panels of the rear portion. Figure 17A shows the rear portion 100 with non-fused zones 51-54 of the first panel 1 and the second panel 2 at each of the strap connection portions 120 such that a portion of the strap is located between the first panel 1 and the second panel 2 and the components are attached to one another such as by welding. Figure 17B then shows each strap welded between the first panel 1 and the second panel 2 at each of the strap connection portions 120.

[1030] The strength of the fusion connection between the strap and the rear section may depend on the type of strap utilized and its material properties. For example, in the case of some types of fabric laminate foam that may be used as a strap, the fusion connection, or more specifically the welded connection, between the laminate foam and the rear section may be relatively strengthened if the laminate foam is welded to the non-fused portion of the rear section.

[1031] More specifically, if the laminate foam is welded to a single panel that is not fused, rather than two or more stacked panels that are not fused, the connection may be relatively stronger.

[1032] 74 shows headgear 10 having a rear portion 100 with a first panel 1 and a second panel 2. In the lateral extension of the rear portion, the first panel 1 extends beyond the second panel 2 and defines strap connection portions 120a and 120b of the first panel 1. Straps 200a / 301 and 200b / 303 are overlapped against strap connection portions 120a and 120b and fused together with the first panel 1.

[1033] 74, straps 200a / 301 and 200b / 303 are overlapped against the patient-facing side of the first panel 1 (opposite the second panel 2). In other configurations, straps 200a / 301 and 200b / 303 may be overlapped against the non-patient-facing side of the first panel.

[1034] Although straps 200a / 301 and 200b / 303 at strap connection portions 120a and 120b are shown in FIG. 74 as only partially overlapping with the first panel 1, in other configurations the non-overlapping portions of the first panel 1 at strap connection portions 120a and 120b may be of sufficient size to allow the full width of the strap to be overlapped thereagainst.

[1035] Strap attachment by fusion bonding to the non-overlapping portions of the first panel 1 may be used with any one or more of the straps of the headgear, including any lower straps 302 and 304 of the headgear.

[1036] As mentioned above, it may be desirable to limit variations in the curve and width of the headgear straps to increase the yield of the material or materials from which the straps are formed. Figure 75 shows a configuration in which headgear 10 includes separate straps 200a, 200b and 301-304.

[1037] With the exception of strap end feature 330 of second upper strap 200b, each of the straps 200a, 200b and 301-304 of the headgear 10 of FIG. 75 has a constant width along their respective lengths.

[1038] Although the second top strap 200b is shown with a wider end having a slot for receiving the end of the first top strap 200a, it will be understood that other forms of attachment between the top straps may be used, such as a buckle or hook and loop fastener system, to allow the second top strap 200b to have a constant width along its entire length.

[1039] As shown in Fig. 75, each of the straps 200a, 200b, 302 and 304 are also straight along their entire length. The upper side straps 301 and 303 are also straight except for a single curve towards the ends attached to the rear portion 100. These curves may help position the strap ends in the desired proximity of the strap connection fixtures of the patient interface in use.

[1040] However, in other configurations, the upper side straps 301 and 303 may be completely straight along their length.

[1041] 75, straps 200a, 200b and 301-304 are positioned over the overlapping first and second panels and fused to the second panel 2 at the overlap region 21 of the rear portion 100. This provides headgear 10 in which straps 200a, 200b and 301-304 are generally located on the non-patient-facing side of the headgear.

[1042] Although in FIG. 75 the straps are shown fused only to the second panel 2 and not to the non-overlapping portions 31 of the first panel 1, in some configurations the straps may be fused to both the second panel 2 and the first panel 1 where they overlap.

[1043] For example, as discussed above in connection with Figures 48A-48D, connection of the straps to the rear portion of the headgear may be facilitated by insertion of the strap ends into pockets in the rear portion.

[1044] 76 shows a further embodiment of headgear 10 having first and second top straps 200a and 200b and two pairs of upper and lower side straps 301-302 and 303-304. Each of the straps is connected to the rear portion 100 by inserting each strap end into a respective notch 530 in the second panel 2.

[1045] If the first panel 1 and second panel 2 are fused together prior to connecting the straps, the fusion may leave unfused areas adjacent the respective cutouts 530 to define pockets 531 that accommodate the ends of the respective straps, as described in connection with Figures 48A-48D. Once inserted into the pockets, the strap ends and the first and second panels may then be fused together.

[1046] If the first panel 1 and the second panel 2 are fused together at the same time that the strap is fused thereto, there is no need to predefine a pocket between the first and second panels since the strap end can simply be inserted between the first and second panels which are not fused.

[1047] 76, each of the straps 200a, 200b, 301-304 has a continuous width and is straight, except for the ends of the side straps 301-304 and the strap connection fasteners of the second strap 200b in the pockets of the rear portion 100. Although the strap ends of the side straps 301-304 are shown angled relative to the remainder of each side strap, in other configurations the strap ends connected to the headgear may not be angled relative to the remainder of each respective strap.

[1048] Fig. 77A shows another form of strap connection to the rear portion 100. As seen in Fig. 77A, the ends of the individual straps 200a, 200b and 301-304 each pass through a respective slot 571-576 in the strap connection portion of the rear portion 100. The strap end is then folded back and connected to itself. This connection may be of a releasable form using, for example, a hook and loop fastener system.

[1049] Instead, as shown in Fig. 77A and in more detail in Fig. 77B, when inserted into the slot in the rear portion, the strap may be fused to itself as indicated by fused zone 41. Fusion of the strap to itself may be preferred when the strap is made from a fabric laminated foam, which may fuse more effectively to another fabric laminated foam than to a textile alone, such as the first panel 1 or the second panel 2.

[1050] The slots 571 - 574 may be slots that extend through the thickness of the rear portion 100 , for example, through both the first panel 1 and the second panel 2 .

[1051] In other configurations, for example if it is desired to position the straps away from the patient-contacting side of the rear portion, the slots 571-574 may extend only through one or more of the outer panels of the rear portion. In this configuration, the strap ends would extend through their respective slots and enter the pockets between the first panel 1 and the second panel 2 before folding back on themselves.

[1052] In FIG. 77A, a slot is formed in one or more panels of the rear portion 100 to accommodate the attachment of a strap, however, in other forms, a portion of the slot may be formed in the strap to allow for the connection of other straps.

[1053] For example, in FIG. 78, first top strap 200a and second top strap 200b are formed with slots 571 and 574 that receive top side straps 301 and 303.

[1054] In the configuration of FIG. 78, top straps 200a and 200b each overlap a rear portion to the lateral-most extent of ear loop 320.

[1055] Slots 571 and 574 may be slots that extend only through the top straps 200a and 200b, or may be slots that extend through the top straps 200a or 200b and one or more of the panels of the rear portion 100 over which they are stacked.

[1056] The top strap portions 200a and 200b may be provided as part of two of the side straps, as shown, for example, in FIG. 74. In other configurations, they may be provided as separate pieces, as shown, for example, in FIG. 75. In yet other configurations, the top strap portions 200a and 200b may comprise one continuous piece, as shown and described above in connection with FIG. 34. A top strap comprising a continuous piece of material may enhance the ability to transfer loads between the ends of the top strap without relying entirely on the material of the rear portion 10 to transfer the load. The use of a top strap comprising a continuous piece of material also eliminates the need for a separate top strap attachment fastener on the rear portion.

[1057] 79A shows an upper strap 200 having two upper strap ends 200a and 200b with a relatively thin central portion 200c connecting them. The upper strap 200 has a straight shape. Its non-curved formed shape may allow for relatively improved yields of the substrate or substrates on which it is formed.

[1058] FIG 79B shows the top strap 200 of FIG 79A incorporated as part of the headgear 10 sandwiched and fused between the first panel 1 and the second panel 2. The central portion 200c of the top strap 200 is relatively thin so that it may be molded to follow the curve of the top edge of the rear portion with minimal out-of-plane warping or distortion. This configuration may provide the headgear with a continuous, curved top strap 200 and improved material yields versus the top strap 200 being itself formed into the desired curved shape.

[1059] The upper strap 200 may be formed from a fabric laminated foam.

[1060] If the characteristics of the straps and rear portion of the headgear allow the straps to be reliably fused to their own material rather than to the panels of the rear portion, the rear portion may have additional sections of the same material as the straps added to act as strap connection portions.

[1061] 80 shows headgear 10 with two wishbone-shaped strap material portions 575 and 576 superimposed on the second panel 2 at each lateral extent of the rear portion 100. For example, if the straps are made from fabric laminated foam, the strap material portions 575 and 576 may also be fabric laminated foam.

[1062] Straps 200a and 200b and upper side straps 301 and 303 are laid over and fused to strap material portions 575 and 576, respectively.

[1063] The strap material portions 575 and 576 may be fused to the rear portion 100. Alternatively, the strap material portions 575 and 576 may be secured to the rear portion 100 by other methods, such as adhesives or stitching, especially if a fused connection between the two materials may not provide sufficient strength.

[1064] The thinned, wishbone-like configuration of strap material portions 575 and 576 may mean that they can be cut in a straight shape and then curved when applied to the rear portion without causing excessive distortion.

[1065] Although shown in FIG. 80 as a single piece on each side of rear portion 100, sections of strap material may be provided separately in the rear portion for one or more of the straps of the headgear.

[1066] The strap material portion may be fabric laminated foam, particularly if the strap is fabric laminated foam, although the strap material portion may alternatively be an adhesive, such as a hot melt adhesive.

[1067] Figure 81 illustrates another embodiment of headgear 10 incorporating strap material portions 575 and 576 to aid in connecting straps 200a, 200b and 301-304 to rear portion 100. As can be seen in Figure 81, strap material portions 575 and 576 each extend continuously between the three strap connection points on each lateral side of the rear portion.

[1068] The straps and rear portion of the headgear may not only be joined together, but may also be indirectly connected using an intervening piece.

[1069] For example, as shown in FIG. 82A, two straps 200a and 301 can be inserted into an overmold piece 580, which is then connected to the rear portion 100 of the headgear. In FIG. 82A, an attachment post 581 depends from the overmold piece 580. The attachment post 581 has a barbed or mushroom-like shape and includes a base 581b that connects to the overmold piece 580 and a head with laterally extending wings 581a. As seen in FIG. 82A, the rear portion 100 has a notch 582. The length of the notch 582 is less than the length of the attachment post 581 between its two lateral wings 581a. The rear portion 100 and the strap assembly are connected by passing the notch 582 over the attachment post 581 to be held by the wings 581a.

[1070] With this configuration, the strap assembly may be removably connected to the rear portion of the headgear, which may allow the strap or set of straps or the rear portion to be changed, for example to replace worn items or to provide different sizes, without having to replace the entire headgear.

[1071] The headgear 10 is shown in FIG. 82B with respective overmold pieces 580 overmold onto straps 200a and 301 and 200b and 303 and connected to rear portion 100 by attachment posts 581.

[1072] Although the rear portion 100 is shown in FIGS. 82A and 82B as connecting to the strap assembly by an attachment post 581, the rear portion may also be overmolded to form a permanent connection rather than a removable connection.

[1073] As mentioned above, it may be desirable to locate the connection point of one or more straps of the headgear away from the patient-facing side of the rear portion, which may improve the continuity or smoothness of the patient-facing side of the headgear and therefore improve the comfort of the headgear.

[1074] However, it may be desirable to connect both sides of the straps to the rear portion rather than only connecting one side of the straps, which may increase the strength of the connection, which may also reduce twisting of the headgear at the joints.

[1075] 83A shows the strap connection portion 120 of the rear portion 100. At the strap connection portion 120, the rear portion 100 includes an extension 58. The strap 300 is overlapped on one side against the rear portion 100 at the strap connection portion 120, and the extension 58 is folded over the strap 300 so as to be overlapped on both sides by the rear portion 100.

[1076] To attach the strap 300 to the rear portion 100, the strap and rear portion may be fused together at the strap connection portion 120, as shown in FIG. 83B.

[1077] While various preferred embodiments utilize fusion to process overlapping areas or join panels at overlapping areas, other methods of joining or processing the panels may be utilized. For example, the panels may be joined through the use of adhesives, or the various panels or panel portions may include sewn joints, especially in locations where such stitching may not undesirably affect the bulk of the headgear or especially the thickness of the joints and the patient's comfort when wearing the headgear. Panels may be further joined through the use of fasteners to hold the panels together.

[1078] The adhesive may be applied between the panels to be joined, or it may additionally or alternatively be applied to overlapping panels, such as by dipping or immersing the panels in the adhesive.

[1079] The term adhesive is understood to encompass any one or more of the types or combinations of commonly available adhesives. The adhesive may be, for example, an acrylic adhesive, an anaerobic adhesive, or a cyanoacrylate adhesive.

[1080] The adhesive may be, for example, an ester- or ether-based compound. More specifically, it may include nylon-polyamide, or may be nylon-polyamide, ester-polyurethane, polyester, or polyolefin.

[1081] The adhesive may need to be activated to initiate or accelerate the process of curing the adhesive to form a bond between overlapping panels, particularly when the adhesive is provided as a solid or semi-solid, but potentially also when the adhesive is a liquid or gel. For example, in the case of a solid or semi-solid adhesive, the adhesive may be activated by melting from a solid or semi-solid state. In other forms, the adhesive may be activated by the combination of two components of the adhesive, such as in the case of a two-component acrylic adhesive.

[1082] The process of joining panels by forming a bond with an adhesive is referred to herein as curing the adhesive, although it will be understood that such curing may involve one or more of a chemical reaction within the adhesive or adhesive combination, the presence of a particular environment (such as an anaerobic environment) or contact with a particular type of material (such as an alkaline material), drying, or the application of one or more of pressure, heat, sound, or light, or the formation of a bond by any other commonly employed method for converting an adhesive to a bonded state.

[1083] In one example, the adhesive may be in the form of a solid or semi-solid hot melt adhesive, heat may be applied to activate the adhesive by melting it, and the adhesive may be cured, such as by one of the curing processes described above, to form a bond between each overlapping panel.

[1084] The adhesive may be provided as a separate layer and assembled between the respective panels where it may be activated to form a bond. The adhesive may be applied to areas of one or both of the overlapping panels during assembly of the panels, particularly if the adhesive is a liquid or gel adhesive.

[1085] If the adhesive is in the form of a hot melt adhesive, it may be provided as a tape. This tape or sheet of adhesive may be cut to form the desired planar shape to provide the desired bonding area of ​​the panels.

[1086] Such tape or sheet hot melt adhesives may further include a tacky or adhesive surface or surface coating so that the adhesive may provide at least some temporary retention of the panels to which it is assembled before the adhesive is activated.

[1087] According to various embodiments, adhesives may be used in conjunction with fusing the panels to join and / or process portions of the headgear, although in at least some preferred embodiments, the use of adhesives may be eliminated. The use of adhesives - or any additional other joining method - inherently results in an increase in either or both of the weight and thickness of the joined panels.

[1088] For example, if an adhesive tape is used, it is laid between the panels to be joined. The adhesive may be fully or partially melted into one or both of the panels, but the adhesive adds weight to the joined panels compared to fusing the panels directly together.

[1089] Although generally shown as being completely overlapped by the first layer, according to various embodiments, the second layer may be only partially overlapped by the first layer.

[1090] Although generally shown as being fused to one another throughout portions of the overlap region, the overlapped panels of the headgear may be fused to one another exclusively or primarily around the boundaries of the overlap region, in which case the boundaries to which the fusion is applied may, however, extend beyond the overlap region onto any adjacent non-overlapping regions.

[1091] According to various aspects of the present disclosure, headgear including multiple panels, each panel at least partially overlapping the other panels and fused together, can be lightweight compared to headgear formed by other methods.

[1092] Headgear according to the present disclosure may have a weight of less than about 30 g, less than about 20 g, or less than about 10 g.

[1093] In particular, various embodiments of headgear 10 according to the present disclosure may have a weight of about 17.5 g to about 27.5 g, and more particularly about 25 g.

[1094] While the foregoing description has referred to various general concepts of overlapping panels together and various features of specific embodiments of headgear formed by such overlapping panels, it is contemplated within the scope of this disclosure that either the general concepts or the features of the specific aspects or embodiments may be combined with each other in any number of different ways to provide headgear or portions thereof.

Claims

1. a rear portion of headgear for a patient interface, the rear portion including a first fabric panel and a second fabric panel, the first fabric panel and the second fabric panel defining an overlap region where the first fabric panel and the second fabric panel overlap one another above and below, respectively, and a non-overlapping region where the first fabric panel is not overlapped; A rear portion, wherein adjacent surfaces of the first fabric panel and the second fabric panel are fused together in the overlap region.

2. The rear section of claim 1 , wherein in the overlap region, the adjacent surfaces of the first and second fabric panels are fused directly to one another without any intervening material.

3. The rear section of claim 1 , wherein the overlap region includes a fused portion and a non-fused portion.

4. 2. The posterior section of claim 1, wherein the overlap region includes a transition zone between a fused portion and a non-fused portion, the transition zone defining a degree of fusion between the non-fused portion and the fused portion, and the transition zone including a gradient in the degree of fusion between the fused portion and the non-fused portion.

5. a) a fused portion of the overlapping region; b) a non-fused portion of the overlap region; and c) the non-overlapping area of ​​the first fabric panel. The rear section of claim 1 , wherein each of said rear sections includes different stretch characteristics.

6. The rear section of claim 1 , wherein adjacent surfaces of the first fabric panel and the second fabric panel at a periphery of the overlap region are fused together.

7. A rear portion as described in any one of claims 1 to 6, wherein the second fabric panel is completely overlapped by the first fabric panel, and the adjacent surfaces of the first fabric panel and the second fabric panel are fused together around the entire peripheral edge of the second fabric panel.

8. The rear portion of claim 7 , wherein the periphery of the overlap region includes opposing boundaries of the periphery of the overlap region.

9. 9. The rear portion of claim 8, wherein the first fabric panel and the second fabric panel in the overlap region are fused together continuously across the overlap region between two or more points on the periphery of the overlap region.

10. A rear portion as described in claim 2, wherein the first fabric panel and the second fabric panel are fused together throughout substantially all of the overlap area.

11. A rear portion as described in claim 1, wherein the non-overlapping region is provided at a lower peripheral portion of the rear portion along one or more curved portions of the overlapping region.

12. The rear portion of claim 11, wherein the non-overlapping region at the lower periphery of the rear portion has a varying width.

13. A rear portion as described in claim 11, wherein the non-overlapping region at the lower peripheral edge of the rear portion has an edge having a radius of curvature smaller than the radius of curvature of an adjacent curved portion of the overlapping region.

14. A rear portion as described in claim 13, wherein the non-overlapping area at the lower peripheral portion of the rear portion defines one or more crescent shapes.

15. A strap fastener comprising: a central section having laterally spaced strap connection portions; The rear section of claim 1 , wherein the non-overlapping region is a first non-overlapping region located between laterally spaced strap connection portions of the central section.

16. A vehicle seat comprising: lateral sections on either side of said central section, each lateral section having a strap connection portion in its lateral extent; 16. The aft section of claim 15, wherein the aft section includes a second non-overlapping region located at a lateral periphery of the aft section between each strap connection portion of the lateral section and a respective strap connection portion of the central section.

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