Respiratory interface assembly

Abstract

To provide a headgear of a respiratory interface assembly.SOLUTION: A respiratory interface assembly includes a patient interface 152, such as a nasal mask, and a headgear arrangement 154. The headgear arrangement can have one or more semi-rigid straps, which can be a composite construction of an outer fabric and a plastic core. The outer fabric can be knitted. The headgear arrangement can include a composite rear portion having an upper strap and lower strap, which are configured to be adjustable relative to one another.SELECTED DRAWING: Figure 2

Description

Technical Field

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

Background Art

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

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

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

Summary of the Invention

Means for Solving the Problems

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

[0006] One aspect of the present disclosure includes a rear portion of a respiratory mask headgear including an integral body portion including a plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion includes a junction between the first end of the upper strap and the first end of the lower strap. The junction includes a base portion and a transition region between the base portion and one of the upper strap and the lower strap. The base portion defines a width. The width of the transition region is less than the width of the base portion of the junction and the width of each upper strap or lower strap to which the transition region is joined.

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

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

[0009] In some configurations, the transition region defines a length that is less than the width of the base portion of the junction and / or the width of each upper strap or lower strap to which the transition region is joined.

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

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

[0012] In some configurations, the junction is symmetric about an axis passing between the junction and the upper strap and the lower strap.

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

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

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

[0016] In some configurations, the main strap portion defines the entire one of the upper edge portion and the lower edge portion of the strap.

[0017] In some configurations, the main strap portion defines the full width of the central portion of the strap.

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

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

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

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

[0022] In some configurations, the central portion of the upper strap defines a length smaller than the length of the central portion of the lower strap.

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

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

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

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

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

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

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

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

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

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

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

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

[0035] In some configurations, the lower strap width may be made larger than the upper strap width.

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

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

[0038] In some configurations, the joint between the first end of the upper strap and the first end of the lower strap is the first joint, and further includes a second joint between the second end of the upper strap and the second end of the lower strap. The second joint includes a transition region between the base portion and one or both of the upper strap and the lower strap.

[0039] One aspect of the present disclosure includes a respiratory mask headgear including any of the above-described rear portions and a pair of side straps. Each of the side straps extends from one of each of the first joint and the second joint. Each of the side straps includes an elongate plastic member coupled to the plastic material of the body portion of the rear portion.

[0040] In some configurations, each elongate plastic member of the side straps is joined to the plastic material of the body portion by an overmolded connection portion.

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

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

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

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

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

[0046] One aspect of the present disclosure includes a respiratory mask assembly including any one of the above-mentioned headgears, a respiratory mask, and a first directional lock and a second directional lock coupled to the respiratory mask. Each elongate plastic member of the side straps includes a filament portion, and each filament portion of the side straps passes through one of each of the first directional lock and the second directional lock. Each of the first directional lock and the second directional lock is configured to provide a first resistance force against movement of the filament portion in a first direction tending to extend the side strap and a second resistance force against movement of the filament portion in a second direction tending to shorten the side strap, and the first resistance force is greater than the second resistance force.

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

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

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

[0050] One aspect of the present disclosure includes a rear portion of a respiratory mask headgear including an integrally formed body portion including a plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion includes a joint at the joint between the first end of the upper strap and the first end of the lower strap, the joint including a base portion and a living hinge between the base portion and one of the upper strap and the lower strap.

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

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

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

[0054] In some configurations, the joint is symmetric about an axis passing between the joint and the upper and lower straps.

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

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

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

[0058] In some configurations, the main strap portion defines the entirety of one of the upper and lower edges of the strap.

[0059] In some configurations, the main strap portion defines the full width of the central portion of the strap.

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

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

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

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

[0064] In some configurations, the central portion of the upper strap defines a length smaller than the length of the central portion of the lower strap.

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

[0066] In some configurations, the body portion includes a fabric inner layer, a fabric outer layer, and an internal plastic layer, and the internal plastic layer is permanently joined as an integral structure by introducing the internal plastic layer in a molten state into the space between the fabric inner layer and the fabric outer layer and curing it.

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

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

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

[0070] In some configurations, the junction between the first end of the upper strap and the first end of the lower strap is the first junction, and further includes a second junction between the second end of the upper strap and the second end of the lower strap, and the second junction includes a living hinge between the base portion and one or both of the upper strap and the lower strap.

[0071] One aspect of the present disclosure includes a respiratory mask headgear including any one of the above-mentioned rear portions and a pair of side straps. Each of the side straps extends from one of each of the first junction and the second junction. Each of the side straps includes an elongate plastic member coupled to the plastic material of the body portion of the rear portion.

[0072] In some configurations, the elongate plastic member of each side strap is coupled to the plastic material of the body portion by an overmolded connection portion.

[0073] In some configurations, each of the side straps includes a hub at an end of the elongate plastic member, and the hub includes a port configured to receive the molten plastic material forming the body portion of the rear portion.

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

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

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

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

[0078] One aspect of the present disclosure includes a respiratory mask assembly including any of the above-mentioned headgears, a respiratory mask, and a first direction lock and a second direction lock coupled to the respiratory mask. Each elongate plastic member of the side straps includes a filament portion, and each filament portion of the side straps passes through one of each of the first direction lock and the second direction lock, and each of the first direction lock and the second direction lock is configured to provide a first resistance force against the movement of the filament portion in a first direction in which the side strap tends to extend and a second resistance force against the movement of the filament portion in a second direction in which the side strap tends to shorten, and the first resistance force is greater than the second resistance force.

[0079] In some configurations, the first resistance force is configured to prevent the movement of the filament portion in the first direction corresponding to the blowing-off force generated by the respiratory mask.

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

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

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

[0083] One aspect of the present disclosure includes a rear portion of a respiratory mask headgear that includes an integral body portion including a plastic material. The body portion includes an upper strap having a lower edge, a first end, a second end, a length between the first end and the second end, and a width. The body portion also includes a lower strap having an upper edge, a first end, a second end, a length between the first end and the second end, and a width. A separation distance is defined between the lower edge of the upper strap and the upper edge of the lower strap. A junction is located between the ends of the upper strap and the ends of the lower strap. The junction includes a base portion and a flex region between the base portion and one of the upper strap and the lower strap. The flex region is configured to pivot each upper strap or lower strap to which the flex region is joined relative to the base portion of the junction and increase the separation distance.

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

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

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

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

[0088] In some configurations, the flex region defines a length that is less than the width of the base portion of the joint and / or the width of each upper strap or lower strap to which the flex region is joined.

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

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

[0091] In some configurations, the joint is symmetric about an axis passing through the joint and between the upper and lower straps.

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

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

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

[0095] In some configurations, the main strap portion defines the entirety of one of the upper and lower edges of the strap.

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

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

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

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

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

[0101] In some configurations, the central portion of the upper strap defines a length that is smaller than the length of the central portion of the lower strap.

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

[0103] In some configurations, the body portion includes a fabric inner layer, a fabric outer layer, and an internal plastic layer that is permanently joined as an integral structure by introducing the internal plastic layer in a molten state into the space between the fabric inner layer and the fabric outer layer and curing it.

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

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

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

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

[0108] One aspect of the present disclosure includes any of the above-described rear portions and a pair of side straps, each of the side straps extending from one of each of the first joint and the second joint, and each of the side straps including a respiratory mask headgear including an elongate plastic member coupled to the plastic material of the body portion of the rear portion.

[0109] In some configurations, the elongate plastic member of each side strap is coupled to the plastic material of the body portion by an overmolded connection.

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

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

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

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

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

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

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

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

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

[0119] One aspect of the present disclosure includes a rear portion of a respiratory mask headgear including an integral body portion including a plastic material. The body portion includes an upper strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion also includes a lower strap having a first end, a second end, a length between the first end and the second end, and a width. The body portion includes a first junction and a second junction. The first junction is located between the first end of the upper strap and the first end of the lower strap, and the second junction is located between the second end of the upper strap and the second end of the lower strap. Each of the upper strap and the lower strap includes a main strap portion having a first thickness and at least one flange portion having a second thickness smaller than the first thickness. The main strap portion extends along the entire length of the strap from the first junction to the second junction. The at least one flange portion extends along most of the length of the strap.

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

[0121] In some configurations, the main strap portion or the main strap portion and the flange define the entire width of the strap at any location along the length of the strap.

[0122] In some configurations, the main strap portion defines the entirety of one of the upper and lower edges of the strap.

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

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

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

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

[0127] In some configurations, each of the first joint and the second joint includes a base portion and a flex region between the base portion and one or both of the upper strap and the lower strap, and the flex region is configured to pivot each upper strap or lower strap to which the flex region is joined relative to the base portion and increase the separation distance between the lower edge of the upper strap and the upper edge of the lower strap.

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

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

[0130] One aspect of the present disclosure includes a pair of side straps of a respiratory mask headgear that can each include an elongate plastic member and a support housing. The elongate plastic member can include a first portion, a second portion, a hub, and a transition portion. The first portion can include a first end and a second end. The second end can include a mechanical stop that extends radially outward from the elongate plastic member. The mechanical stop can define an expansion hard stop. The second width can be smaller than the width of the first portion. The hub can include a first end that faces the second end. The second end of the hub can include a contact surface that can define a retraction hard stop. The second end of the hub can be adjacent to the first end of the first portion. The transition portion can be disposed between the second end of the first portion and the second end of the second portion. The support housing can be configured to constrain at least a portion of the elongate plastic member. The support housing can define an internal channel configured to receive the elongate plastic member. The support housing can include an outer collar, an inner collar, and an intermediate portion between the outer collar and the inner collar.

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

[0132] In some configurations, each of the side straps can further include at least one length that can include a maximum length and a minimum length.

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

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

[0135] In some configurations, the hub may substantially include a rectangle, and the length of the hub may be made greater than the width of the hub.

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

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

[0138] In some configurations, the hub and the first part may each include an outer surface and an inner surface.

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

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

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

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

[0143] One aspect of the present disclosure includes a respiratory mask headgear including any one of the pairs of straps described above and a rear portion. The rear portion may include an integral body portion including a plastic material. The integral body portion may include an upper strap, a lower strap, a first junction, and a second junction. The upper strap may have a first end, a second end, a length between the first end and the second end, and a width. The lower strap may have a first end, a second end, a length between the first end and the second end, and a width. The first junction may be disposed between the first end of the upper strap and the first end of the lower strap. The second junction may be disposed between the second end of the upper strap and the second end of the lower strap. Each of the side straps may extend from one of each of the first junction and the second junction. The first end of the hub of each side strap may be overmolded onto one of each of the first junction and the second junction. The second end of the hub of each side strap may remain uncovered.

[0144] One aspect of the present disclosure includes a pair of side straps of a respiratory mask headgear, each including an elongate plastic member. The elongate plastic member may include a first portion, a second portion, and a hub. The first portion may include a first end, a second end, an inner surface, an outer surface, and a first portion thickness measured between the inner surface and the outer surface of the first portion. The width of the second portion may be made smaller than the width of the first portion. The hub may include a first end opposite the second end, a first side opposite the second side, an inner surface, an outer surface continuous with the outer surface of the first portion, and a hub thickness measured between the inner surface and the outer surface of the hub. The hub thickness may be made larger than the first portion thickness. The second end of the hub may be adjacent to the first end of the first portion and may include a contact surface defining a retraction hard stop. The first side and the second side of the hub may extend between the first end and the second end of the hub and may be separated by the longitudinal axis of the first portion. The first length of the first side of the hub may be made larger than the second length of the second side of the hub. The first width of the first side of the hub may be made larger than the second width of the second side of the hub.

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

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

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

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

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

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

[0151] In some configurations, the offset between the second end of the first side of the hub and the second end of the second side of the hub can define a directional notch.

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

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

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

[0155] In some configurations, the mechanical stop may include a serrated edge and an inclined surface.

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

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

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

[0159] In some configurations, the outer collar may be configured to abut against the mechanical stop of the elongate plastic member.

[0160] One aspect of the present disclosure includes a rear portion of a respiratory mask headgear that can be formed from a unitary structure of molten plastic formed into a three-dimensional shape. The unitary structure of molten plastic can include an integrally molded upper strap and an integrally molded lower strap. The integrally molded upper strap can have a first end, a second end, and a first length between the first end and the second end. The integrally molded upper strap can include a first curvature configured to approximate or conform to the shape of the upper portion of a user's head. The integrally molded lower strap can have a first end, a second end, and a second length between the first end and the second end. The integrally molded lower strap can include a second curvature configured to approximate or conform to the shape of the lower or rear portion of a user's head. The first end of the upper strap can form a first junction with the first end of the lower strap, and the second end of the upper strap can form a second junction with the second end of the lower strap.

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

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

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

[0164] In some configurations, the first junction and / or the second junction can include a base portion and a flex region. The flex region can be disposed between the base portion and one of the upper strap and the lower strap.

[0165] In some configurations, the upper strap and / or the lower strap can include a relatively harder or reinforced portion having a greater thickness than adjacent portions of the upper strap and / or the lower strap.

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

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

[0168] The foregoing and other features of the present disclosure will become more fully apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. It is to be understood that the drawings illustrate only some embodiments of the present disclosure and are not to be considered as limiting its scope, and the present disclosure will be described in more specific and detailed manner through the use of the accompanying drawings.

Brief Description of the Drawings

[0169]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figures 9A - 9D

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

Figures 23A - 23D

Figure 24

Figure 25

Figure 26

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30A

Figure 30B

Figure 30C

Figure 30D

Figure 31

Figure 32

Embodiments for Carrying Out the Invention

[0170] Reference is now made to the accompanying drawings, in which like numbers refer to like or similar elements throughout, and embodiments of systems, components, and methods of assembly and manufacture will be described. The following discloses several embodiments, examples, and explanations, but it will be understood by those skilled in the art that the invention described herein extends beyond the specifically disclosed embodiments, examples, and explanations, and may include other uses of the invention and its obvious modifications and equivalents. The terms used in the description presented herein are not intended to be construed as limiting or restrictive merely because they are used in conjunction with a detailed description of specific embodiments of the invention. Further, embodiments of the invention may include several novel features, and no single feature is necessarily the sole factor responsible for its desirable characteristics or essential for the practice of the invention as described herein.

[0171] In the following description, certain terms may be used for reference purposes only and are thus not intended to be limiting. For example, terms such as "above" and "below" refer to directions within the referenced drawings. Terms such as "front," "back," "left," "right," "rear," and "side" describe the orientation and / or position of a component or portion of a component within a consistent but arbitrary coordinate system that becomes apparent by reference to the text describing the component or element in question and the associated drawings. Further, terms such as "first," "second," "third," etc., may be used to describe separate components. Such terms may include those specifically mentioned above, their derivatives, and words of similar import.

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

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

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

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

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

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

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

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

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

[0181] Mask 152 may also include an exhaust port or vent to allow exhaled and excess breathing gas to exit the breathing chamber of the mask 152. In some configurations, the vent may be a bias flow vent that includes a plurality of vent holes. The bias flow vent may be located in the mask frame 156 or in other suitable portions of the mask 152, such as the cushion module or the connecting tube 164. In some configurations, the bias flow vent may include a diffuser that covers the plurality of vent holes to diffuse the exhausted gas and reduce the velocity of the exhausted gas and / or the noise generated by the exhausted gas. The diffuser may be removable from the mask 152 for cleaning or replacement, or may be permanently attached to a portion of the mask 152 by a molding process such as placing the diffuser material in a mold and then injecting a suitable plastic material (e.g., polycarbonate) into the mold to create a one-piece structure. The diffuser material may be directly overmolded onto the frame 156. In other embodiments, the diffuser material may be overmolded onto a clip. The clip has an engaging portion for engaging complementary engaging features in another portion of the mask 152, which is for attaching the clip (and associated diffuser material) to that portion of the mask 152.

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

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

[0184] The illustrated front portion 200 includes straps 212 that connect to the mask 152 via suitable connectors such as clips on each side of the interface assembly 150. In the illustrated configuration, the straps 212 on each side of the interface assembly 150 are separate from each other and connect to the mask 152 separately. The front straps 212 can be mirror images of each other. Thus, unless otherwise specifically indicated herein, the details described herein for one strap 212 can be considered to apply to the other strap 212 as well, except for the symmetric state.

[0185] Each strap 212 extends from the mask 152 across the user's cheek to the junction 220 with the rear portion 210. Since the strap 212 extends generally along the side of the user's head, the strap 212 may be referred to herein as a "side strap". In the illustrated configuration, each side strap 212 extends in a slightly upward direction from the end closer to the mask 152 toward the end closer to the junction 220. Each side strap 212 extends toward or to a position above the user's ear. In some configurations, the rear end of each side strap 212 may be located directly above or above the line of the user's ear and slightly in front of or slightly behind the user's ear.

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

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

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

[0189] The rear portion 210 of the headgear 154 can define a specific angle 240 and / or a separation distance 242 in a relaxed or neutral position. The relaxed or neutral position can be the position of the rear portion 210 defined by the formed or forming tool in the embodiment being formed. The relaxed or neutral position can be the position of the rear portion 210 when no external force tending to deform the rear portion 210 is applied. Such an angle 240 or separation distance 242 can be referred to as a static angle 240 or a static separation distance 242.

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

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

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

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

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

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

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

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

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

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

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

[0201] The structure of the transition region 352 and / or the junction 220 and straps 230, 232 that are adjacent to and include the transition region 352 and / or the flex region 354 may form a living hinge structure. A living hinge, which may be referred to as a flex joint, flex bearing, or bending bearing, is a flexible segment or portion of material that joins two relatively more rigid segments or portions. The hinge is flexible and bendable, allowing movement of the attached segments or portions. A living hinge is typically made of the same material as the two more rigid portions to which the living hinge is connected. This applies to the integral rear portion 210 disclosed herein. A living hinge is typically thinned or cut away to allow the rigid portions to be bent along the line of the hinge. A living hinge does not include a defined pivot structure. The low wear and minimal friction of the living hinge are advantageous for an adjustable rear portion 210 that may be exposed to many adjustment cycles and may be used by persons with weak hand strength and / or low dexterity. A living hinge may be substantially the same size as the transition region 352 and / or the flex region 354 compared to the much larger structure of the rear portion 210, such as the base portion 350 of the junction 220 and straps 230, 232. Accordingly, the dimensions and relative sizes described herein with respect to the transition region 352 and / or the flex region 354 may equally apply to the living hinge.

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

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

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

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

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

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

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

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

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

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

[0212] In some configurations, the main strap portion 380 or both the main strap portion 380 and the flange 382 define the entire widths 300, 302 of the straps 230, 232 at any position along the lengths 284, 294 of the straps 230, 232. As described above, in the illustrated configuration, the main strap portion 380 defines the entire widths 300, 302 of the central portions 310, 312 of the straps 230, 232. Such a configuration may enable the straps 230, 232 to maintain a relatively large arc in a neutral state to facilitate donning and removal by the user. Further, the load applied to the central portions 310, 312 (the rear portion when worn) is greater than the load applied to the end portions (the side portions when worn). Therefore, it is desirable that the torsional resistance and / or bendability in the central portions 310, 312 be greater.

[0213] In some configurations, the length 400 of the central portion 310 or the main strap portion 380 within the central portion 310 of the upper strap 230 may be different from the length 402 of the central portion 310 or the main strap portion 380 within the central portion 310 of the lower strap 232. As shown in FIG. 5, the length 400 of the upper strap 230 is smaller than the length 402 of the lower strap 232. Thus, the lower strap 232 can have a larger arc (e.g., a larger diameter) than the upper strap 230, thereby facilitating the distinction between the straps 203, 232 by the user and / or better conforming to the typical user's head shape. In some configurations, the length 400 can be about 50 mm to 100 mm, about 60 mm to 90 mm, about 70 mm to 80 mm, or about 75 mm. The length 402 can be about 75 mm to 125 mm, about 85 mm to 115 mm, about 95 mm to 105 mm, or about 100 mm. In other configurations, this configuration can be reversed, the length 400 can be made larger than the length 402, or the lengths 400, 402 can be made the same. The lengths 400, 402 can be defined as the maximum length, minimum length, or average length of the main strap portion 380 within the central portions 310, 312.

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

[0215] The plastic core 270 can be made from any suitable material or combination of materials. In some configurations, the plastic core 270 can be made from a thermoplastic elastomer (TPE) material such as a polyether block amide (PEBA). An example of such a material is sold under the brand name Pebax® by Arkema S.A., Colombes, France. In particular, the material can be Pebax® 2533. In some configurations, the material can have a Shore hardness of about 10 to 40 Shore D, about 20 to 30 Shore D, or about 22 to 27 Shore D. Such materials can provide a plastic core 270 that has some elasticity or allows for a certain amount of stretch. As further described below, the elasticity of the plastic core 270 can be modified by the fabric layers 260, 262 or other coverings. Alternatively, the plastic core 270 can be made from a silicone material that can provide a desired amount of flexibility. A low Shore hardness, such as within the above ranges, provides a “hard fabric” feel to the rear portion 210 of the headgear 154. In other words, the rear portion 210 of the headgear 154 is recognized by the user as a hard fabric strap rather than a plastic strap with a fabric covering. Advantageously, the disclosed rear portion 210 has the characteristics of a typical fabric headgear strap, such as a soft texture, feel, visual appeal, and flexibility, but has the shape memory of plastic. The upper and lower straps 230, 232 are flexible, but the structure of the rear portion 210 of the headgear 154 is maintained without the straps 230, 232 folding or tangling like a typical fabric strap. Such a configuration enhances the usability and convenience of the headgear 154.

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

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

[0218] FIG. 8 shows a mold tool 420 that can be used to form the rear portion 210 of the headgear 154. As described above, the fabric layers 260, 262 can be disposed within a portion or half 424, 426 of the mold cavity 422 of the mold tool 420. The mold tool 420 includes a stop 428 that forms the protruding edge 410 of the fabric layers 260, 262. The stop 428 can define a space sized and shaped to receive the protruding edge 410, but is small enough that little or no plastic material can enter. Thus, the plastic core 270 can have a shape with a rounded upper and lower edge defined by the shape of the portion of the mold tool 420 adjacent to the stop 428 as shown in the figure. To form the plastic core 270 and permanently bond the fabric layers 260, 262 to the plastic core 270, molten plastic material is introduced into the mold cavity 422 of the mold tool 420 between the fabric layers 260, 262 and cured.

[0219] As shown in FIG. 2, the fabric layers 260, 262 can also extend along a portion or all of the front portion 200 of the headgear 154 or the side strap 212. The side strap 212 may desirably be able to vary in length in order to allow the headgear 154 to conform to various users and / or to facilitate the donning and doffing of the headgear 154. In some configurations, the headgear 154 is configured to provide easy adjustment to a size suitable for an individual user.

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

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

[0222] In use, the user places the mask 152 at a predetermined position on their face and overcomes the first resistance force provided by the direction lock 430 to pull the rear portion 210 of the headgear 154, increasing the closed loop perimeter so that the rear portion 210 of the headgear 154 can be placed on the rear portion of the user's head. The user can release the rear portion 210 of the headgear 154, reduce the closed loop perimeter with a suitable elastic member, and overcome the second resistance force provided by the direction lock 430 to move the mask assembly 150 towards or to a suitable closed loop perimeter for a particular user. When treatment is initiated, the direction lock 430 prevents or inhibits an increase in the closed loop perimeter in response to normal or expected forces during use. When treatment is complete, the user can grasp the rear portion 210 of the headgear 154, overcome the first resistance force, increase the closed loop perimeter, and remove the mask assembly 150.

[0223] In some configurations, as described above, the side straps 212 provide for a change in the closed loop perimeter of the mask assembly 150. Further, the side straps 212, particularly the fabric layers 260, 262, provide an elastic force that tends to reduce the closed loop perimeter against the second resistance force provided by the direction lock 430. In some configurations, the direction lock 430 is located on each side of the mask assembly 150. The direction lock 430 can be supported by the mask 152 and can interact with a portion of the associated side strap 212. Thus, the first resistance force can prevent an extension movement of the associated side strap 212, and the second resistance force can prevent a shortening movement of the associated side strap 212. The side straps 212 can extend between the mask 152 and the rear portion 210 of the headgear 154, be connected to the mask 152 and the rear portion 210 of the headgear 154, apply an elastic or biasing force that tends to shorten the side strap, and reduce the closed loop perimeter or move the mask 154 towards the rear portion 210 of the headgear.

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

[0225] As described above, the plastic core 270 can be made from a material having some elasticity or allowing some amount of stretch. The non-elastic material, relatively non-elastic material, or generally non-elastic characteristics of the rear portion 442 of the cover 440 can modify the elasticity or stretchability of the plastic core 270. The combination of the elastic or stretchable material of the core 270 and the non-elastic material of the cover 440 results in the rear portion 210 being able to be relatively non-elastic or substantially non-elastic, yet providing an advantageous level of flexibility. The permanent connection between the cover 440 and the plastic core 270 can facilitate or enhance a relatively high level of flexibility with little likelihood of exceeding an acceptable amount of stretch. The resulting rear portion 210 can be considered non-stretchable or substantially non-stretchable. As used herein, a substantially non-stretchable headgear component does not exceed an acceptable amount of stretch and can maintain an interface at a predetermined position on the user's face at an appropriate location for delivering a desired treatment.

[0226] In some configurations, the braided tubular cover 440 can be formed by an appropriate braiding process using an appropriate material such as the processes and materials described herein. The braided cover 440 can be formed as a single piece including one or more of the side strap 212, the upper strap 230, and the lower strap 232. In other words, the braided cover 440 can be formed by braiding a single piece including a branch from the side strap 212 to the upper and lower straps 230, 232 via the joint 220.

[0227] The braided cover 440 can be braided into a shape that approximates or substantially matches the final shape of the headgear 154 that is partially determined by the die cavity of the die tool 420. With such a configuration, the stitch structure and the braiding direction generally or substantially match the shape of the plastic core 270 determined by the die cavity of the die tool 420. The rear portion 210 of the resulting headgear 154 has a braided edge that matches the curvature of the plastic core 270, and the deposition and / or accumulation of materials can be reduced compared to a fabric covering made from a flat sheet material.

[0228] Referring to FIGS. 1 and 9A - 10, as described above, different portions 442, 444 of the cover 440 can be made of different materials or combinations of different materials. For example, in the illustrated configuration, the rear or non - elastic portion 442 of the knitted cover 440 is created using a first material 450 such as a first thread or filament type (e.g., the meshed fibers of FIG. 10). In some configurations, the first material 450 is nylon (e.g., textured nylon) or includes nylon (e.g., textured nylon). Textured nylon provides bulk, stability, and a comfortable texture for the user at the back of the head. In the illustrated configuration, for the front portion 200 or side straps 212, a second material 452 such as a second thread or filament type (e.g., the non - meshed fibers of FIG. 10) is used. In some configurations, the second material 452 is an elastane material (e.g., Lycra) or includes an elastane material (e.g., Lycra). In some configurations, the second material 452 is elastane wrapped with nylon (e.g., double - nylon - wrapped elastane).

[0229] As shown in FIG. 10, the transition between the rear portion 442 and the front portion 444 can include both the first material 450 and the second material 452. In the transition portion, both the first material 450 and the second material 452 are knitted over a specific number of rows. Such a process is called intarsia knitting. The purpose of the transition portion and intarsia knitting is to provide reinforcement and strength at the junction between the non - elastic portion 442 and the elastic portion 444. In some configurations, intarsia knitting can extend over a majority or all of one of the upper strap 230 or lower strap 232. Such a configuration can provide different textures between the straps 230, 232 and can assist the user in distinguishing between the upper strap 230 and the lower strap 232.

[0230] In some configurations, the cover 440 can be woven horizontally, starting from one side strap 212, proceeding over and under the upper and lower straps 230, 232 of the rear portion 210, and ending at the other side strap 212. Alternatively, the cover 440 can be woven from top to bottom or from bottom to top. At the transition between the first side strap 212 and the rear portion 201, the above-described weft knitting technique can be applied to one of the upper strap 230 or the lower strap 232 to transition from the second material 452 to the first material 450. When a thread or filament of the second material 452 of the elastic portion 444 is cut in one of the upper strap 230 or the lower strap 232, an additional thread or filament of the first material 450 can be introduced and woven to form the other of the upper strap 230 and the lower strap 232. When the rear portion 210 is woven, the weft knitting technique can be repeated, and the second side strap 212 can be formed from the second material 452.

[0231] Referring to FIGS. 2 and 9A-9D, the materials used to make the cover 440 can vary to provide color, pattern, and / or texture variations to the headgear 154 to facilitate differentiation between different portions of the headgear 154 (e.g., between the straps 212, 230, 232), or to provide visual or tactile interest, or both. As shown in FIGS. 2 and 9A-9D, a first color can be provided to a portion or all of the rear portion 210 of the headgear 154, and a second different color can be provided to a portion or all of the front portion 200. As shown in FIG. 9D, the transition between the front portion 200 and the rear portion 210 can include additional colors or designs, such as stripes or bands, to function as a gradual transition. Further, either or both of the front portion 200 and the rear portion 210 can include multiple colors, patterns, or textures.

[0232] Figures 9A-9C also show possible variations in the shape of the junction 220. For example, the slot 370 (FIG. 4) can take different shapes to provide different shapes to one or more of the base portion 350, the transition region 352, or the ends 280, 282, 290, 292 of the straps 230, 232. Exemplary shapes of the slot 370 can include triangles, quadrilaterals (e.g., rhomboids, rhombuses (FIG. 9C), squares, trapezoids), pentagons (FIG. 9A), other polygons, round or circular shapes (FIG. 9B), combinations of the above, etc. Further examples of alternative junctions 220 are disclosed herein with reference to FIGS. 23A-23D.

[0233] As described above, the mask assembly 150 uses one or more directional locks 430 that provide different resistances for different directions of movement between the mask 152 and the headgear 154. The side strap 212 provides a change in the closed-loop perimeter of the mask assembly 150 and provides an elastic force that tends to reduce the closed-loop perimeter against the second resistive force provided by the directional lock 430. In the illustrated configuration, the directional lock 430 is located on each side of the mask assembly 150 and interacts with a portion of the associated side strap 212. As shown in FIGS. 11 and 12, the headgear 154 includes an elongate plastic member 460 that is coupled to the rear portion 210 of the headgear 154, extends along the side strap 212, and engages the directional lock 430 (FIG. 11). In the illustrated configuration, the elongate plastic member 460 extends within the cover 440 or between the layers 260 and 262 of the cover 440.

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

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

[0236] The end of the elongate plastic member 460 on the side opposite the second portion 464 includes a hub 466. The hub 466 can facilitate the connection of the elongate plastic member 460 to the rear portion 210 of the head gear 154. The hub 466 can engage the rear portion 210. In some configurations, the hub 466 or the adjacent portion of the hub 466 and the first portion 462 of the elongate plastic member 460 can be joined to the rear portion 210 by an overmolded joint, as shown in FIG. 11. In particular, the plastic core 270 of the rear portion 210 can be overmolded onto or over the hub 466 or the adjacent portion of the hub 466 and the first portion 462 of the elongate plastic member 460. The hub 466 can be located within the base portion 350 of the joint 222. In some configurations, the length 467 of the hub 466 can be about 5 mm to 10 mm, about 6 mm to 9 mm, about 7 mm to 8 mm, or about 7.5 mm.

[0237] The hub 466 can generally be configured to facilitate the molding of the plastic core 270 or the overmolding of the plastic core 270 onto the elongate plastic member 460. Referring to FIGS. 13-18, the hub 466 can include an inlet or port 480 configured to receive the molten plastic material forming the plastic core 270. In some configurations, the diameter of the port 480 can be about 1 mm to 5 mm, 2 mm to 4 mm, or about 3 mm. The hub 466 can include an internal channel or flow path 482. The internal channel or flow path 482 is connected to the port 480 and is open to the outer surface of the hub 466. In the illustrated configuration, the flow path 482 extends in the width direction across the entire hub 466. In some configurations, the length 481 of the flow path 482 can be about 1 mm to 5 mm, about 2 mm to 4 mm, or about 2.5 mm. In some configurations, the thickness or height 483 of the flow path 482 can be about 0.5 mm to 3 mm, about 1 mm to 2 mm, or about 1 mm. The molten plastic material received within the port 480 can pass through the flow path 482 and exit the hub 466 to create the plastic core 270.

[0238] In the illustrated configuration, the hub 466 includes a first wall or cap 490 and a second wall or cap 492. The first cap 490 can be an outer - side cap 490 that is located on the outer side of the headgear 154 during use, and the second cap 492 can be an inner - side cap 492 that is located on the inner side of the headgear 154 during use. The outer - side cap 490 and the inner - side cap 492 can be formed separately or in a separate state and can be joined together to form the hub 466. For example, the outer - side cap 490 can be connected to a first portion 462 of the elongate plastic member 460. The inner - side cap 492 can be connected to the outer - side cap 490 by a hinge connection 494. However, this configuration can be reversed.

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

[0240] The hub 466 can be molded or fabricated with the outer - side cap 490 and the inner - side cap 492 arranged in an orientation such that they are in the same plane as shown in FIG. 13. After molding, the inner - side cap 492 can be connected to the outer - side cap 490 by bending the hinge 494 to create a hub 466 as shown in FIGS. 14 - 18. In the illustrated configuration, each of the outer - side cap 490 and the inner - side cap 492 defines a portion of the depth of the flow path 482. However, in other configurations, either the outer - side cap 490 or the inner - side cap 492 can define the entire depth of the flow path 482.

[0241] Referring to FIGS. 19 and 20, the elongate plastic member 460 is inserted into the cover 440 before overmolding with the plastic core 270. In FIGS. 19 and 20, for clarity, a portion of the side strap 212 is cut away (shown by the dashed line). In particular, the elongate plastic member 460 can be inserted into the open front end of the side strap portion 444 of the cover 440 as indicated by the arrow in FIG. 19. The portion of the cover 440 surrounding the joint 220 of the plastic core 270 can include holes 510 having a size and / or shape similar to or slightly smaller than the ports 480 of the hub 466. In other configurations, the holes 510 can be sized and / or shaped to be slightly larger than the ports 480. In other configurations, the holes 510 can be omitted and the molten plastic material can pass directly through the braided cover 440, or a portion of a molding tool (e.g., an injection needle) can pass through the braided cover 440 through gaps between the threads of the braided cover 440. The holes 510 can be created by or after the braiding process. The elongate plastic member 460 is disposed within the cover 440 such that the ports 480 are aligned with the holes 510 as shown in FIG. 20.

[0242] The cover 220 and the elongate plastic member 460 can be disposed within a molding tool such as the molding tool 420 of FIG. 8. The elongate plastic member 460 can include features to assist in positioning or maintaining the proper position of the elongate plastic member 460 within the molding tool 420. For example, a first portion 462 of the elongate plastic member 460 adjacent to the hub 466 can include one or more alignment features or alignment holes 512. The one or more alignment features or alignment holes 512 cooperate with appropriate structures (e.g., pins or protrusions) within the molding tool 420 to secure the elongate plastic member 460 in a desired position within the mold cavity 422.

[0243] The mold tool 420 may define an inlet or runner (not shown) of the mold cavity 422 that is aligned with the hole 510 and the port 480 of the hub 466. The molten plastic material forming the plastic core 270 is introduced into the mold cavity 422 through the inlet or runner, passes through the hole 510, the port 480, and the flow path 482, enters the space between the layer 260 and the layer 262 of the rear portion 442 of the cover 440, and can form the plastic core 270 within the cover 440. The inner side cap 392 located opposite the port 480 can prevent or stop the molten plastic injected directly from the inlet or runner from penetrating through the braided cover. FIG. 20 shows the rear portion 210 of the headgear with the plastic core 270 formed therein and permanently connected to the rear portion 442 of the cover 440. A suitable connector (not shown) for connecting to the frame 156 of the mask 152 can be coupled to the free end of the side strap portion 444 of the cover 440 by any suitable configuration or process, such as overmolding, that can be performed in the same or a different process as the formation of the plastic core 270.

[0244] FIG. 21 shows an alternative embodiment of the elongate plastic member 460 having an alternative hub 466. In other respects, the elongate plastic member 460 may be the same as or similar to the elongate plastic member 460 described above. The hub 466 of FIG. 21 includes a single wall 490 that may generally correspond to the outer side cap 490 of the previous embodiment. Under at least some conditions, there may be no need for an inner side cap 492 or other structure opposite the port 480 to block or redirect the flow of molten plastic. In such situations, a simplified hub 466 configuration can be used.

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

[0246] FIGS. 23A - 23D show additional further alternative joints 220 that may provide the same or similar adjustment characteristics as the above-described embodiments. The joint 220 of FIG. 23A includes a generally triangular slot 370 that creates a transition region 352 and a flex region 354 between the base portion 350 of the joint 220 and each of the upper strap 230 and the lower strap 232. The joint 220 of FIG. 23B includes a generally rhomboidal slot 370 that creates a transition region 352 and a flex region 354 between the base portion 350 of the joint 220 and each of the upper strap 230 and the lower strap 232. The joint 220 of FIG. 23C includes a generally pentagonal slot 370 that creates a transition region 352 and a flex region 354 between the base portion 350 of the joint 220 and each of the upper strap 230 and the lower strap 232. The joint 220 of FIG. 23D includes a generally circular slot 370 that creates a transition region 352 and a flex region 354 between the base portion 350 of the joint 220 and each of the upper strap 230 and the lower strap 232. The joint 220 of FIG. 23D has a more gradual transition between the transition region 352 and the straps 230, 232.

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

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

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

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

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

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

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

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

[0255] In some configurations, as shown in FIG. 26, the braided cover 440A may include a constant or substantially constant width over the length of the braided cover 440A. The constant or substantially constant width of the braided cover 440A can reduce the time taken for the braiding process. Further, as described above, the transition regions 352A, 352B of the plastic core 270A may have reduced widths 362A, 362B (FIG. 25) with respect to the base portion 350A of the joint 220A and / or the upper strap 230A and / or the lower strap 232A. In some configurations, the braided cover 440A may have a slight taper in the transition regions 352A, 352B such that the braided cover 440A has a smooth curve along the transition regions 352A, 352B. For example, the reduction in the width of the braided cover 440A from the widest part to the narrowest part of the braided cover 440A can be about 10% - 30% or about 15% - 25%. During manufacturing, the width of the braided cover 440A can be tapered by, for example, tightening the knit of the braided cover 440A towards the joint 220A where the upper strap 230A and the lower strap 232A contact to minimize the length of the braided cover 440A at the base of the joint 220A.

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

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

[0258] Referring to FIGS. 27-29, the hub 466A may substantially include a rectangle. For example, the lengths 712, 716 of the hub 466A may be made larger than the width 717 of the hub 466A. In some configurations, the lengths 712, 716 of the hub 466A may be about 10 mm to 15 mm, about 12 mm to 14 mm, or about 13 mm. In some configurations, the width 717 of the hub 466A may be about 5 mm to 10 mm, about 7 mm to 8 mm, or about 9 mm. In some configurations, the thickness 718 of the hub 466A may be about 1 mm to 5 mm, about 2 mm to 4 mm, or about 2 mm. In some configurations, the diameter of the port 480A may be about 1 mm to 5 mm, about 2 mm to 4 mm, or about 2 mm. As shown in the illustrated configuration, the port 480A may be disposed on the hub 466A such that the port 480A is aligned with or near the central position of the joint 220A (FIG. 26). In some configurations, the port 480 may be disposed at other locations of the hub 466.

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

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

[0261] As shown in the illustrated configuration, the second side portion 704 may include an orientation notch 708 and / or the first side portion 702 may include an orientation key 709. In some configurations, the hub 466A may include a first end 701 and a second end 703 that may be integral with or attached to the first portion 462A of the elongated plastic member 460A. In the illustrated configuration, the first end 701 of the hub 466A may be continuous along each of the first and second side portions 702, 704. Also, the second end 703 of the hub 466A may include an offset 707 such that the second end 711 of the first side portion 702 is offset from the second end 713 of the second side portion 704. In some configurations, the second end 703 of the hub 466A may be continuous, but the first end 701 of the hub 466A may include an offset. In some configurations, the ends 701, 703 may be continuous or may include an offset. During manufacturing, the hub 466A and the first portion 462A of the elongated plastic member 460A may be placed into a cavity of the three-dimensional mold tool described above or the mold tool 420 described in connection with FIG. 8 to overmold the hub 466A onto the plastic core 270A. This overmold process may be the same as or similar to the overmold process described elsewhere in this disclosure. The orientation notches 708, the orientation keys 709, and / or the asymmetry of the hub 466A may reduce the risk of the elongated plastic member 460A being assembled incorrectly. For example, the asymmetry of the hub 466A may prevent incorrect orientation with respect to the two orientations shown in FIGS. 27 and 28. Additionally, as described above, the orientation of the hub 466A may be different on each side of the headgear 154.

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

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

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

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

[0266] As described above and referring to FIGS. 31 and 32, the elongate plastic member 460A can include a relatively wider first portion 462A and a relatively narrower second portion 464A. In some configurations, the first portion 462A can have a width of about 3.5 mm, while the second portion 464A can have a width of about 0.86 mm. In some configurations, the elongate plastic member 460A can include a transition region 748 between the first portion 462A and the second portion 464A where the width of the elongate plastic member 460A tapers from the wider first portion 462A to the narrower second portion 464A. In one example, the length of the first portion 462A including the transition region 748 can be about 100 mm, and the length of the second portion 464A can be about 95 mm. However, these lengths can be variable depending on other features of the direction lock 430.

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

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

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

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

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

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

[0273] In this specification, numerical data may be expressed or presented in a range format. Such a range format is used merely for convenience and brevity, and thus should be interpreted flexibly not only to include the numerical values explicitly listed as the limits of the range, but also to include all of the individual numerical values or sub-ranges subsumed within that range as if each numerical value and sub-range had been explicitly listed. For example, a numerical range of "about 1 to 5" should be interpreted to include not only the explicitly listed values of about 1 to about 5, but also the individual values and sub-ranges within the indicated range. Thus, included within this numerical range are the individual values such as 2, 3, and 4, and sub-ranges such as, for example, "about 1 to about 3", "about 2 to about 4", and "about 3 to about 5", "1 to 3", "2 to 4", "3 to 5", etc. This same principle applies to ranges that indicate only a single numerical value (e.g., "greater than about 1"), and should apply regardless of the breadth of the range or the property being described. For convenience, multiple items may be presented within a common list. However, these lists should be interpreted as if each element of the list were individually identified as a distinct and unique element. Thus, the individual elements of such a list should not be interpreted, absent an indication to the contrary, as de facto equivalents of any other element of the same list based solely on the fact that they are presented within a common group. Further, when the terms "and" and "or" are used in conjunction with a list of items, these should be interpreted broadly in that any one or more of the listed items may be used alone or in combination with any other of the listed items. The term "alternatively" refers to selecting one of two or more alternatives and is not intended to limit the selection to only the listed alternatives or to only one of the listed alternatives at a time, unless explicitly indicated in the context.

Claims

1. A rear portion of a respiratory mask headgear, 1. A unitary body portion comprising a plastic material, an upper strap having a first end, a second end, a length between the first end and the second end, and a width; a bottom strap having a first end, a second end, a length between the first end and the second end, and a width; a juncture between the first end of the upper strap and the first end of the lower strap, the juncture including a base portion and a transition area between the base portion and one of the upper strap and the lower strap, the base portion defining a width; a one-piece body portion including Including, a width of the transition region is less than the width of the base of the joint and the width of each of the upper straps or lower straps to which the transition region is joined; Rear part of breathing mask headgear.

2. 2. The rear portion of a respiratory mask headgear according to claim 1, wherein the width of the transition region is less than about one-half the width of each of the top straps or bottom straps to which it is joined.

3. 2. The rear portion of a respiratory mask headgear according to claim 1, wherein the width of the transition region is less than about one-third the width of each of the top straps or bottom straps to which it is joined.

4. 4. A rear portion of a respiratory mask headgear according to any one of claims 1 to 3, wherein the transition region defines a length that is less than the width of the base of the joint and / or the width of each of the upper straps or lower straps to which the transition region is joined.

5. 5. A rear portion of respiratory mask headgear according to claim 4, wherein the length of the transition region is less than about two-thirds or one-half of the width of each of the upper or lower straps to which the transition region is joined.

6. 6. A rear portion of a respiratory mask headgear according to any one of claims 1 to 5, wherein the transition area is defined by a slot, the slot having a maximum width that is less than the width of the base of the junction and / or the width of each of the upper or lower straps adjacent to the slot.

7. A rear portion of a respiratory mask headgear according to any one of claims 1 to 6, wherein the joint is symmetrical about an axis passing through the joint and between the upper strap and the lower strap.

8. 8. A rear portion of a respiratory mask headgear according to any one of claims 1 to 7, wherein each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, the main strap portion extending along the entire length of the strap and the at least one flange portion extending along the majority of the length of the strap.

9. 9. The rear portion of the respiratory mask headgear of claim 8, wherein the at least one flange portion extends along only a portion of the length of the strap.

10. 10. A rear portion of respiratory mask headgear according to claim 8 or 9, wherein the main strap portion, or the main strap portion and the flange, define the overall width of the strap anywhere along the length of the strap.

11. A rear portion of respiratory mask headgear according to any one of claims 8 to 10, wherein the main strap portion defines the entirety of one of the upper and lower edges of the strap.

12. A rear portion of respiratory mask headgear according to any one of claims 8 to 11, wherein the main strap portion defines the overall width of the central portion of the strap.

13. A rear portion of a respiratory mask headgear according to any one of claims 8 to 12, wherein the at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

14. 14. A rear portion of respiratory mask headgear according to claim 13, wherein in use each of the first and second flange portions extends along substantially the entirety of each side of a user's head.

15. 15. A rear portion of a respiratory mask headgear according to any one of claims 1 to 14, wherein the length of the upper strap is a first length and the length of the lower strap is a second length, the second length being greater than the first length.

16. A rear portion of a respiratory mask headgear according to any one of claims 1 to 15, wherein the width of the lower strap is greater than the width of the upper strap.

17. A rear portion of respiratory mask headgear according to any one of claims 12 to 16, wherein the central portion of the upper strap defines a length that is less than a length of the central portion of the lower strap.

18. 18. A rear portion of a respiratory mask headgear according to any one of claims 1 to 17, wherein the transition region is a first transition region and the juncture further comprises a second transition region, the first transition region being located between the base portion and the upper strap and the second transition region being located between the base portion and the lower strap.

19. 20. The rear portion of a respiratory mask headgear according to claim 18, wherein the second transition region has a width greater than the width of the first transition region.

20. 20. The rear portion of a respiratory mask headgear according to any one of claims 1 to 19, wherein the body portion comprises an inner fabric layer, an outer fabric layer, and an inner plastic layer, the inner plastic layer being permanently joined as a unitary structure by introducing the inner plastic layer in a molten state into a space between the inner fabric layer and the outer fabric layer and curing.

21. 21. The rear portion of the respiratory mask headgear of claim 20, wherein the inner fabric layer and the outer fabric layer are knitted.

22. 22. A rear portion of a respiratory mask headgear according to claim 20 or 21, wherein the inner fabric layer and the outer fabric layer are joined to form an edge fabric layer along the upper and lower edges of the upper and lower straps.

23. 23. The rear portion of the respiratory mask headgear of claim 22, wherein a thickness of the edge fabric layer along the upper and lower edges of the upper and lower straps is greater than a thickness of the inner and outer fabric layers.

24. 2. The rear portion of the respiratory mask headgear of claim 1, further comprising at least one fabric layer configured to encase the inner plastic layer, the at least one fabric layer comprising at least one width, the at least one width comprising a transition region width disposed adjacent the transition region.

25. 25. The rear portion of the respiratory mask headgear of claim 24, wherein the at least one fabric layer includes at least one upper strap fabric layer and at least one lower strap fabric layer.

26. 26. The rear portion of the respiratory mask headgear of claim 25, wherein the at least one width comprises an upper strap width of the at least one upper strap fabric layer and a lower strap width of the at least one lower strap fabric layer.

27. 27. The rear portion of the respiratory mask headgear of claim 26, wherein the at least one fabric layer includes an upper strap width along the upper strap and a lower strap width along the lower strap.

28. 28. A rear portion of respiratory mask headgear according to claim 27, wherein the transition region width is the same as or similar to the top strap width.

29. 28. A rear portion of respiratory mask headgear according to claim 27, wherein the transition region width is the same as or similar to the bottom strap width.

30. 28. A rear portion of respiratory mask headgear according to claim 27, wherein the lower strap width is greater than the upper strap width.

31. 25. The rear portion of the respiratory mask headgear of claim 24, wherein the transition region width of the at least one fabric layer is greater than the width of the transition region of the juncture.

32. 32. The rear portion of the respiratory mask headgear of claim 31 , wherein the at least one fabric layer includes at least one fabric flap adjacent the transition region, the width of the at least one fabric flap being greatest where the width of the transition region is smallest.

33. 33. A rear portion of a respiratory mask headgear according to any one of claims 1 to 32, wherein the junction between the first end of the upper strap and the first end of the lower strap is a first junction and further comprises a second junction between the second end of the upper strap and the second end of the lower strap, the second junction comprising a transition region between the base portion and one or both of the upper strap and the lower strap.

34. 1. A unitary body portion comprising a plastic material, an upper strap having a first end, a second end, a length between the first end and the second end, and a width; a bottom strap having a first end, a second end, a length between the first end and the second end, and a width; a juncture between the first end of the upper strap and the first end of the lower strap, the juncture including a base and a living hinge between the base and one of the upper strap and the lower strap; a one-piece body portion including The rear portion of the breathing mask headgear.

35. 35. A rear portion of respiratory mask headgear according to claim 34, wherein the living hinge defines a length that is less than a width of the base of the joint and / or the width of each of the upper or lower straps to which it is joined.

36. 36. A rear portion of respiratory mask headgear according to claim 35, wherein the length of the living hinge is less than about two-thirds or one-half of the width of each of the upper or lower straps to which it is joined.

37. A rear portion of respiratory mask headgear according to any one of claims 34 to 36, wherein the living hinge is defined by a slot.

38. A rear portion of a respiratory mask headgear according to any one of claims 34 to 37, wherein the joint is symmetrical about an axis passing through the joint and between the upper strap and the lower strap.

39. 39. A rear portion of a respiratory mask headgear according to any one of claims 34 to 38, wherein each of the upper and lower straps includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, the main strap portion extending along the entirety of the length of the strap from the first junction to the second junction, and the at least one flange portion extending along the majority of the length of the strap.

40. 40. A rear portion of respiratory mask headgear according to claim 39, wherein the at least one flange portion extends along only a portion of the length of the strap.

41. 41. A rear portion of respiratory mask headgear according to claim 39 or 40, wherein the main strap portion, or the main strap portion and the flange, define the overall width of the strap anywhere along the length of the strap.

42. A rear portion of respiratory mask headgear according to any one of claims 39 to 41, wherein the main strap portion defines the entirety of one of the upper and lower edges of the strap.

43. A rear portion of respiratory mask headgear according to any one of claims 39 to 42, wherein the main strap portion defines the overall width of a central portion of the strap.

44. 44. A rear portion of a respiratory mask headgear according to any one of claims 39 to 43, wherein the at least one flange portion includes a first flange portion and a second flange portion located on either side of the central portion of the strap.

45. 45. A rear portion of respiratory mask headgear according to claim 44, wherein, in use, each of the first and second flange portions extends along substantially the entirety of each side of the user's head.

46. 46. ​​A rear portion of a respiratory mask headgear according to any one of claims 34 to 45, wherein the length of the upper strap is a first length and the length of the lower strap is a second length, the second length being greater than the first length.

47. A rear portion of respiratory mask headgear according to any one of claims 34 to 46, wherein the width of the lower strap is greater than the width of the upper strap.

48. A rear portion of respiratory mask headgear according to any one of claims 43 to 47, wherein the central portion of the upper strap defines a length that is less than a length of the central portion of the lower strap.

49. 49. A rear portion of a respiratory mask headgear according to any one of claims 34 to 48, wherein the living hinge is a first living hinge and the joint further comprises a second living hinge, the first living hinge being located between the base portion and the upper strap and the second living hinge being located between the base portion and the lower strap.

50. 1. A unitary body portion comprising a plastic material, an upper strap having a first end, a second end, a length between the first end and the second end, and a width; a bottom strap having a first end, a second end, a length between the first end and the second end, and a width; a first junction between the first end of the upper strap and the first end of the lower strap; a second junction between the second end of the upper strap and the second end of the lower strap; a one-piece body portion including Including, each of the upper strap and the lower strap includes a main strap portion having a first thickness and at least one flange portion having a second thickness less than the first thickness, the main strap portion extending along the entire length of the strap from the first junction to the second junction, and the at least one flange portion extending along a majority of the length of the strap; Rear part of breathing mask headgear.

51. 51. A rear portion of respiratory mask headgear according to claim 50, wherein the at least one flange portion extends along only a portion of the length of the strap.

52. 52. A rear portion of respiratory mask headgear according to claim 50 or 51, wherein the main strap portion, or the main strap portion and the flange, define the overall width of the strap anywhere along the length of the strap.

53. A rear portion of respiratory mask headgear according to any one of claims 50 to 52, wherein the main strap portion defines the entirety of one of the upper and lower edges of the strap.

54. 54. A rear portion of respiratory mask headgear according to any one of claims 50 to 53, wherein the main strap portion defines the overall width of a central portion of the strap.

55. 55. A rear portion of a respiratory mask headgear as claimed in claim 54, wherein the at least one flange includes a first flange and a second flange located on either side of the central portion of the strap.

56. 56. A rear portion of respiratory mask headgear according to claim 55, wherein in use each of the first and second flange portions extends along substantially the entirety of each side of the user's head.

57. 57. A rear portion of a respiratory mask headgear according to any one of claims 50 to 56, wherein the length of the upper strap is a first length and the length of the lower strap is a second length, the second length being greater than the first length.

58. 58. A rear portion of a respiratory mask headgear according to any one of claims 50 to 57, wherein each of the first and second joints includes a base portion and a flex area between the base portion and one or both of the upper strap and the lower strap, the flex area being configured to allow the respective upper strap or the lower strap to which the flex area is joined to pivot relative to the base portion to increase the separation distance between the lower edge of the upper strap and the upper edge of the lower strap.

59. 60. A rear portion of a respiratory mask headgear according to claim 58, wherein the base portion defines a width and the flex zone includes a transition region defining a width that is less than the width of the base portion at the joint and the width of each of the upper straps or lower straps to which the flex zone is joined.

60. 60. A rear portion of a respiratory mask headgear according to claim 58 or 59, wherein the flex area comprises a living hinge.

61. A pair of respiratory mask headgear side straps, each of the side straps comprising: An elongated plastic member, a first portion including a first end, a second end, an interior surface, an exterior surface, and a first portion thickness measured between the interior surface and the exterior surface of the first portion; a second portion, the width of the second portion being less than the width of the first portion; and a hub including a first end opposite a second end, a first side opposite a second side, an inner surface, an outer surface contiguous with the outer surface of the first portion, and a hub thickness measured between the inner surface and the outer surface of the hub; Including, the hub thickness is greater than the first portion thickness; the second end of the hub is adjacent the first end of the first portion and includes an abutment surface defining a retraction hard stop; the first side and the second side of the hub extend between the first end and the second end of the hub and are separated by a longitudinal axis of the first portion; a first length of the first side of the hub is greater than a second length of the second side of the hub; a first width of the first side of the hub is greater than a second width of the second side of the hub; Including an elongated plastic member; A pair of side straps for respirator headgear.

62. 62. The pair of respiratory mask headgear side straps of claim 61 , wherein the first width of the first side of the hub is measured between the longitudinal axis of the first portion and a first outer edge of the first side of the hub, the first outer edge of the hub being substantially parallel to the longitudinal axis of the first portion.

63. 63. The pair of side straps of respiratory mask headgear of claim 61 or 62, wherein the second width of the second side of the hub is measured between the longitudinal axis of the first portion and a second outer edge of the second side of the hub, the second outer edge of the hub being substantially parallel to the longitudinal axis of the first portion.

64. 64. The pair of respiratory mask headgear side straps of any one of claims 61 to 63, wherein the first length of the first side of the hub is measured between the first end and the second end of the hub.

65. 65. The pair of respiratory mask headgear side straps of any one of claims 61 to 64, wherein the second length of the second side of the hub is measured between the first end and the second end of the hub.

66. 66. A respiratory mask headgear side strap pair according to any one of claims 61 to 65, wherein the first end of the first side of the hub is contiguous with the first end of the second side of the hub.

67. 67. The pair of respiratory mask headgear side straps of any one of claims 61 to 66, wherein the second end of the first side of the hub is offset from the second end of the second side of the hub.

68. 68. The respiratory mask headgear side strap pair of claim 67, wherein the offset between the second end of the first side of the hub and the second end of the second side of the hub defines an orientation notch.

69. 69. A respiratory mask headgear side strap pair according to any one of claims 61 to 68, wherein the inner surface of the hub is offset from the inner surface of the first portion.

70. 70. The pair of respiratory mask headgear side straps of claim 69, wherein the offset between the inner surface of the hub and the inner surface of the first portion defines the abutment surface of the hub, the abutment surface being located at the second end of the hub.

71. 71. The pair of respiratory mask headgear side straps according to any one of claims 61 to 70, wherein the second end of the first portion includes a mechanical stop extending radially outward from the exterior surface of the first portion, the mechanical stop defining an extended hard stop.

72. 72. The respiratory mask headgear side strap pair of claim 71, wherein the mechanical stops include toothed edges and beveled surfaces.

73. 73. The pair of respiratory mask headgear side straps of any one of claims 61 to 72, further comprising a support housing configured to restrain at least a portion of the elongated plastic member, the support housing defining an internal channel configured to receive the elongated plastic member, the support housing including an outer collar, an inner collar, and an intermediate portion between the outer collar and the inner collar.

74. 74. The pair of respiratory mask headgear side straps of claim 73, wherein the support housing includes an inner side and an outer side, the outer side of the middle section of the support housing includes an elongated opening and the inner side of the support housing includes a continuous wall.

75. 75. A respiratory mask headgear side strap pair according to claim 73 or 74, wherein the outer collar is configured to abut against the abutment surface of the hub.

76. 76. A respiratory mask headgear side strap pair according to any one of claims 73 to 75, when dependent on claim 71 or 72, wherein the outer collar is configured to abut the mechanical stop on the elongated plastic member.

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