CN117545524A

CN117545524A - Headgear for patient interface

Info

Publication number: CN117545524A
Application number: CN202280036101.7A
Authority: CN
Inventors: T·J·希区柯克; M·J·佩德森; S·P·帕特尔; P·M·弗里斯通; J·阿梅; A·C·M·法恩; B·M·沃尔斯; C·O·L·伊波利托; M·A·迈凯伦; C·J·N·阿马迪奥
Original assignee: Fisher and Paykel Healthcare Ltd
Current assignee: Fisher and Paykel Healthcare Ltd
Priority date: 2021-05-19
Filing date: 2022-05-19
Publication date: 2024-02-09

Abstract

A headgear for a patient interface is disclosed, wherein the headgear includes a first strap panel and a second strap panel. The overlapping panels define an overlap region in which the first panel and the second panel overlap and overlap each other, respectively. The overlapping panels also define a non-overlapping region in which the first panel is not overlapped. At this overlap region, adjacent surfaces of the respective overlapping panels fuse together.

Description

Headgear for patient interface

Technical Field

The present invention relates to headgear for a patient interface.

Background

The breathing interface or mask is used to provide one or more breathing gases, such as air in CPAP therapy (including, for example, in VPAP systems and BiPAP systems), or in NIV or high flow rate therapies, for example.

The respiratory interface may include a nasal interface, an oral interface, or a full-face (i.e., both nasal and oral) interface. Further, the interface may be an indirect interface covering the nose, mouth, or both, or an indirect interface such as an interface including a nasal nozzle or pillow or the like into the nostrils of the wearer.

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

The headgear may also include a top strap (such as a top strap or forehead strap), and the respiratory headgear may take various other forms. For example, the headgear may include only a crown strap or forehead strap or occipital loop, as well as a single strap on either side of the patient's head or facing the mask. Typically, one or more of the headgear straps may be adjustable in length so that the patient can put on the interface and headgear when one or more of the headgear straps are released, then tighten the straps when the interface and headgear are in place, in order to then hold the hood and headgear securely in place until removed or taken off.

Disclosure of Invention

The patient may use various types of respiratory interfaces or masks to provide different respiratory therapies. In order to be able to provide respiratory therapy to a patient, the interface must be held in some way relative to one or both of the patient's mouth and nose. This is especially the case in the following cases: when respiratory therapy involves the provision of a pressurized gas; the mouthpiece must be retained on the patient's face to provide at least some degree of sealing and to prevent unwanted leakage of respiratory therapy gas from the periphery of the mouthpiece. Headgear may be utilized to provide this function of retaining the interface on the patient's face.

The respiratory interface or mask may be used in a variety of environments, including hospital environments and patient homes. Various respiratory therapies may be provided while the patient is awake or sleeping, or both.

While the primary function of the headgear may be to retain the interface relative to the patient's face to counteract any pressure-generated forces and/or form a seal with the patient's face, how the headgear transfers forces to the patient's head may significantly affect patient comfort and potentially their compliance with respiratory therapy. The carrying portion of the headgear may be prone to irritation or discomfort. This may be especially the case in the following cases: when the interface and headgear are to be worn for an extended period of time, such as while sleeping.

In the case of using the interface and headgear while sleeping, at least some portion of the headgear may be located between the patient's head and the bed. This may give the patient more potential for discomfort, as the local thickness of the headgear may result in an increased pressure to which their head is subjected when the headgear is worn.

Different patients may also have significantly different anatomical structures. For example, they may have different head circumference, different facial and skull shapes, and different tissue depths and sensitivities in different regions. This may be exemplified in the back of the patient's head, where some patients may have a neck that is predominantly muscular or significantly tapered from their skull, while others have more adipose tissue or a neck that is not significantly tapered from their skull. These differences may result in different fits or comfort of a given headgear between different patients.

While headgear may be adjusted to fit different patients in some manner, such as by shortening or lengthening one or more straps, such adjustment may not be sufficient to compensate for anatomical differences between patients. Additionally or alternatively, such adjustment may not provide adequate support, or at least a feeling of support, of the headgear on the patient's head. Ideally, the headgear may be adjusted to fit comfortably in the anatomy of the patient, and also to fit firmly and tightly with the patient's head in the adjusted state.

In addition to fit constraints for different patients, it may be desirable for the headgear to perform various secondary functions in addition to retaining the interface on the patient's face. For example, it may be desirable to allow a "pull-apart" function, wherein the headgear in a state that holds the interface to the patient's face allows the user to pull the interface out of contact with his face. This may be to allow the patient to talk more clearly to someone or to provide a brief rest in the therapy.

The headgear itself may have special and local requirements for its structure and function. For example, to retain any given respiratory interface with a certain force, certain areas of the headgear may be subjected to a greater load than other areas. There may also be a location-specific need for stiffness, flexibility, softness, or any number of other characteristics.

Conventional headgear typically consists of one or more joined sections of laminate that includes an outer fabric layer sandwiching an inner foam layer (e.g., natural or synthetic rubber foam). A portion of the headgear is cut from the sheet of laminate and then attached to each other or to other components to form the headgear.

An example of such a laminate for constructing a headgear isIn the case of a headgear made of an existing laminate (e.g. +.>) In the case of the joined sections of (a), the headgear will have a thickness of at least three or more layers that make up the laminate. At the junction between the sections of the laminate, the headgear has a thickness of two joined sections. Even if efforts were made to reduce the thickness of the layers of each laminate, overlapping laminate sections could still easily create undesirably thick areas, creating a potential source of discomfort for the wearer of the headgear. For example, in the case of laminates each having three layers, the resulting joint will have a total of six layers thick.

The foam may deteriorate over time, resulting in a loss of its properties such as its stretch recoverability.

According to the present disclosure, a headgear may be formed from a first panel and a second panel that overlap each other to define an overlap region, and the first panel and the second panel are fused together at the overlap region.

One or both of the first panel and the second panel may partially overlap the other and thus define one or more non-overlapping regions of the headgear.

The panel may be a single sheet panel. Since the headgear may be formed from individual panels comprising a single sheet of material or a composite of materials, rather than from joined layers of multiple layers of different materials. At the non-overlapping region, the headgear includes only a single sheet panelThickness other than in use such asIn the case of a three-layer laminate comprising at least three plies. This may allow for a relative reduction in thickness.

The panel may additionally or alternatively be a multi-ply panel, such as a panel composed of multiple plies or sheets of the same or different materials.

In the overlap region, the headgear of the present disclosure may also have a reduced thickness, or be laminated with two three-layer laminates (such as) In the case of the joint of (c), is the thickness of only two panels compared to six panels.

The panels may be cut to their respective desired shapes and then lapped over and joined to each other. Such a configuration may be different from conventional methods (such as in laminates, such as In the case of a conventional headgear, wherein the headgear is constructed by cutting already laminated panel sections and then joining these panel sections together to form a headgear or a part of a conventional headgear.

In accordance with the present disclosure, a headgear may be formed with a non-overlapping portion, wherein the headgear includes a single panel that is not overlapped by another panel. This configuration is different from, for example, by usingConventional methods of constructing headgear wherein the headgear will always include at least one three layer fabric and foam laminate.

The panels of the headgear may be cut to shape before they are lapped together and joined.

In some forms, at least some portions of the headgear may additionally or alternatively be cut after being overlapped together and potentially after one or more overlapped portions are joined together.

The potential reduction in the number and thickness of panels at the overlap and non-overlap regions of the headgear of the present disclosure may provide a reduction or overall reduction in the thickness of the headgear at a particular location when compared to conventional headgear made from joined laminates or multiple plies of material. The reduced thickness may provide the patient with a visual and/or physical perceived reduction in volume, either at a particular location or throughout the headgear. The reduced thickness may also provide greater comfort to a patient wearing the headgear.

Any such reduction in the number of panels and their thickness at different points of the headgear can correspondingly reduce the overall weight of the headgear.

The panel may exclude any foam material.

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

Conventional headgear laminates comprising foam layers have traditionally not been fused by welding, as welding reduces the cell characteristics of the foam, compresses the foam and makes it rigid. Accordingly, welding of conventional headgear is limited to welding the peripheral portion or edge of the panel overlap region.

Since headgear according to the present disclosure may exclude one or more foam layers, the panels may be fused together over most, or even all, of their overlapping areas. For example, at least a relatively wide dividing line may be fused around the perimeter of the overlap region, as compared to conventional laminated headgear.

Partially or completely eliminating foam material (e.g) It may be permissible to use a different panel material than is required to cover the foam layer. This may, for example, allow for lower cost, thinner and lighter panel materials to be used.

The headgear of the present disclosure may use a panel made of a lightweight and thin textile. Accordingly, the overall thickness as well as the volume and weight of the resulting headgear may be reduced, particularly as compared to conventional headgear constructed from laminated foam.

Headgear according to the present disclosure may utilize fusion to provide desired characteristics of the headgear.

By fusing over a wider path or over a larger area, rather than attempting to fuse only the smallest area, particularly at the perimeter of the overlap of the panels, the tight geometry where the panels are fused by welding can be minimized, thereby reducing problems associated with arc generation and burning that may occur when welding in tight geometry.

The two overlapping panels may be fused together at least around the perimeter of the overlapping region.

The two overlapping panels may be fused together at least around the boundary of the overlapping region.

The two overlapping panels for the rear portion of the headgear may be fused together around the entire perimeter of their overlapping regions, except at one or more strap connection portions of the rear portion. When one or more of the strap attachment portions of the rear portion remain unmelted during manufacture of the rear portion, they may be fused during subsequent manufacture of the headgear. For example, the tie may be interposed between the unfused first and second panels at the or each tie connection region, and then the assembly fused together. With this configuration, the entire perimeter of the overlap region of at least the first and second two panels can be fused, wherein they are directly fused to each other except for the strap connection portion, and indirectly fused to each other at the strap connection portion by fusing to the interposed strap portion.

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

The two overlapping panels of the headgear may be fused to each other over their entire overlapping regions, except in one or more pocket-forming regions of the overlapping panels. An insert (such as a tie end) may be placed within the bag at the bag-forming area prior to the overlapping panels being fused together. Alternatively, the insert may be placed into the bag through the opening after the overlapping panels are fused together. Once the insert is disposed within the pouch, the overlap panel and the insert may be fused together or remain unfused.

The two overlapping panels may be fused together from a first edge of the overlapping region to an opposite edge of the overlapping region.

The two overlapping panels may be fused together over the entire overlap area, except for a smaller area within the interior of the overlap area.

The two overlapping panels may be fused together at substantially the entire overlapping area.

The two overlapping panels may be fused together over the entire overlapping area.

The two overlapping panels may be fused together by fusing the full surfaces of the panels at the overlapping regions.

The two overlapping panels may be fused together such that the fusion occurs along a majority of the length of the line between the two edges of the overlapping region.

The two overlapping panels may be fused together such that the fusion occurs along a majority of the length of any line between the two edges of the overlapping region.

The majority may be any amount from a weak majority to an ensemble.

References to an edge of a headgear (such as an overlap region) or a portion of a headgear will be understood to include any point along the perimeter of that portion.

Unlike conventional stitched joints, which desirably reduce the size of the seam as much as possible to reduce its impact on comfort or visibility, panels joined by fusion can be fused together over a large area without producing a corresponding seam volume or a change in surface finish that would result from a larger stitched area.

When the panels are fused together, their entire adjacent surfaces at the fused portion may be connected to each other. In the case of conventionally stitching the panels together, the panels are only connected together between each successive stitch. Thus, while the stitches may even be tightly placed together and span a large area, the more or less fused areas of the panels may provide a greater degree of connection between the panels than the stitched joints. In other words, by fusing the panels instead of stitching them, a relatively large proportion of the area adjacent to the panel surface may be fixed to each other for a given area to be fused or stitched.

The panel, and in particular the textile panel, is fused over a substantial portion thereof, which may provide the headgear with a strong and flexible character. The fused area may provide a visually clean and uniform surface for the panel. Selectively fusing and unfused different portions of the panels may allow for different material properties in different areas of the same panel or panels. It may also provide for differences in surface characteristics of different areas formed by the same panel or the same panel.

The fabric may be an example of a textile material.

When the two panels overlap to form a headgear or a portion of a headgear, both panels may be textile, such as fabric.

One or both of the two overlapping panels may be made of or comprise a polymeric material.

One or both of the two overlapping panels may be made of or include a dipole material.

The two panels that are fused together may be formed as one integral composite panel at the overlap region, rather than two separate panels being otherwise bonded together or secured to one another.

Fusing the panels may be advantageous over other additive methods of joining the panels together, such as by stitching or using an adhesive. In particular, the weight of the joined panels can be relatively reduced and also the thickness thereof can be reduced.

Forming the headgear entirely or at least primarily by fusing its constituent panels (such as by welding) may provide a more cost effective method of joining the panels together than other conventional methods.

Fusion may additionally or alternatively be applied to the panel at the non-overlapping region of one or more overlapping panels to alter the characteristics of the panel.

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

The non-overlapping of one panel may form a boundary around a portion or all of the other panel. For example, the second panel may be disposed entirely within the confines of the first panel such that the non-overlapping boundary of the first panel extends around the second panel.

A headgear according to the present disclosure may have a non-overlapping region around a portion or the entire perimeter of the headgear.

For example, the headgear may have one or more non-overlapping regions around the upper and lower perimeter of the rear portion of the headgear.

The one or more non-overlapping regions may be formed from the same panel.

The non-overlapping region at the upper periphery of the rear portion of the headgear may be disposed along a substantially straight perimeter of the overlapping region.

The non-overlapping region at the upper periphery of the rear portion may have a substantially continuous width.

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

The non-overlapping region at the lower periphery of the rear portion may have a varying width.

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

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

A headgear according to the present disclosure having first and second overlapping panels defining an overlapping region may be fused around the entire perimeter of the overlapping region.

Fusion around the entire perimeter of the overlap region may provide the first and second panels as a single unitary planar assembly without the panel free edge at the overlap region.

A headgear according to the present disclosure may have a rear portion including first and second overlapping panels and a non-overlapping region of the first panel defining at least a portion of a perimeter of the rear portion.

The non-overlapping region of the first panel includes a border.

When the headgear is worn, the boundaries are located at least at the upper and lower edges of the rear portion.

The border may vary in width in a direction away from the overlap region around the perimeter of the trailing portion.

The boundary provides an edge softening effect.

A headgear or a rear portion for a headgear according to the present disclosure having a first strap panel and a second strap panel that are fused together at the strap region of the panels may include two strap connection portions. When the headgear is assembled, two straps may be connected at the respective strap connection portions of the rear portion. In this configuration, the overlap region may define a continuous fused region of the first panel and the second panel between the two lacing connection portions. The continuous fused region of the first and second panels facilitates transferring loads across the headgear between the straps of the headgear.

The overlap region may define more than one continuous fused region of the first panel and the second panel between the two lacing connection portions.

Where there are more than two lacing connections and a corresponding number of laces connected thereto, the overlap region may define a corresponding continuous fusion zone between each lace and the other lace.

Where there are more than two lacing connections, the overlap region may define a single continuous fusion zone between the individual lacing.

A headgear according to the present disclosure may have first and second depending textile panels that overlap each other to define an overlap region in which the panels are fused together at a welded portion of the second panel.

The welded portion may be the entire second panel at the overlap region such that the first and second panels are fused together over the entire overlap region.

The entire second panel may overlap the first panel.

The second panel is a weldable textile.

The first panel is a non-weldable textile.

The second panel and the first panel may each be a weldable textile.

The first panel and the second panel may each have different stretch characteristics.

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

The first panel and the second panel may define a non-overlap region, and at the overlap region, the first panel and the second panel overlap and overlap each other, respectively, while at the non-overlap region, the first panel is not overlapped.

The first panel and the second panel may define a fused region where they are fused together, and the headgear may have reduced stretch at the fused region as compared to the non-overlapping region of the first panel.

The headgear may have reduced stretch at the fused region as compared to the unfused portion of the second panel.

A headgear according to the present disclosure may include a first and a second depending panel that overlap each other to define an overlap region and are fused together at the overlap region.

In the case of panels fused together, their drape may be reduced.

In the case of panels fused together, the headgear may have a relatively reduced drape as compared to one or more of a) the drape of the first panel, b) the drape of the second panel, or c) the drape of the unfused portion of the overlap region.

The first panel and the second panel may be extensible and the fused portion of the overlap region may have a relatively reduced extensibility.

The first panel and the second panel may be extensible and the fused portion of the overlap region is relatively inextensible.

The first panel and the second panel may be extensible and the fused portion of the overlap region is non-extensible.

According to one aspect, the present disclosure provides a headgear comprising a plurality of panels that overlap one another, wherein the panels are joined together by fusing the panels to one another to define the headgear.

The panels are fused by welding.

The panels are fused by radio frequency welding.

Adjacent landing surfaces of the panels fuse to one another, not just the peripheral edges of the landing portions.

According to another aspect, the present disclosure provides a headgear comprising a first panel and a second panel overlapping one another, wherein the headgear is fused over a substantial portion of the overlapping portion of the first panel and the second panel.

The headgear is fused over a majority of the overlap of the first panel and the second panel.

The headgear is fused around the entire perimeter of the overlapping portions of the first panel and the second panel.

The headgear is also fused at a non-overlapping portion of one or both of the first panel and the second panel.

The first panel and the second panel are joined only by fusion.

The headgear is fused by radio frequency welding.

According to another aspect, the present disclosure provides a method of manufacturing headgear for a patient interface, the method comprising the steps of:

providing a first panel and a second panel partially overlapping the first panel to define an overlap region, an

A weld is applied to the first panel and the second panel,

wherein the step of applying a weld comprises applying a weld to the overlap region and past an outer perimeter of the overlap region.

The step of applying a weld further comprises applying a weld to non-overlapping areas of the first panel and/or the second panel where the panels do not overlap each other.

According to another aspect, the present disclosure provides a headgear comprising a plurality of panels, wherein at least a portion of each panel overlaps at least a portion of the other panel, and the overlapping panels are fused together.

The combination of panels having different characteristics, the overlap interface between the panels, and the amount, degree, or configuration of fused overlap provides the headgear with the potential to achieve location-specific features and characteristics.

According to another aspect, the present disclosure provides a headgear comprising a first panel and a second panel that overlap one another to define an overlap region, and the first panel and the second panel are fused together around a perimeter of the overlap region.

The panels may be fused together around the entire perimeter of the overlap region.

When the second panel is located within the confines of the first panel, the panels may be fused together around the entire perimeter of the second panel.

According to another aspect, the present disclosure provides a headgear comprising two textile panels that overlap one another.

The headgear is comprised of two textile panels and a plurality of lace fixtures.

The two textile panels are partially fused together.

The fusion is performed by welding.

According to another aspect, the present disclosure provides a headgear comprising two fabric panels that overlap one another.

The headgear is comprised of two fabric panels and a plurality of lace securing devices.

The two fabric panels are partially fused together.

The fusion is performed by welding.

According to another aspect, the present disclosure provides a headgear comprising a first panel and a second panel overlapping one another to define an overlap region, and a portion of the overlap region remote from a perimeter thereof being bonded together, wherein the bond is a bond of one or more materials of the first panel and the second panel to one another.

The panels are bonded together without any additional material such as stitching or adhesive.

According to another aspect, the present disclosure provides a headgear for a patient interface comprising first and second overlapping panels defining an overlapping region in which the first and second panels overlap and overlap, respectively, and a non-overlapping region in which the first panel is not overlapped,

wherein at the overlap region, adjacent surfaces of the respective overlapping panels are fused together.

Adjacent surfaces of the respective panels are directly fused to each other at the overlap region without any intervening material.

The overlap region includes a fused portion and an unfused portion.

The overlap region includes a transition between the fused and unfused portions defining a degree of fusion between the unfused and fused portions.

The transition zone includes a degree of fusion gradient between the degree of fusion gradient of the fused portion and the non-fused portion.

Most of the overlap area is fused.

Substantially the entire overlap area is fused.

The headgear includes a third panel, and the first, second, and third panels define an overlap region in which the first panel overlaps and overlaps the second and third panels, respectively, and wherein adjacent surfaces of the first and second panels and adjacent surfaces of the first and third panels are each fused together.

The second panel is completely overlapped with the first panel.

Both the first panel and the second panel are stretchable and the first panel is more stretchable than the second panel.

The second panel has one or more cutouts to define a stretch zone of the first panel within the one or more cutouts.

The second panel is provided in two or more pieces to define one or more zones of extensibility of the first panel between the two or more pieces of the second panel.

The overlapping panels define a fused region where they are fused together, and the headgear has one or more of reduced extensibility, reduced thickness, or a smooth surface at the fused region relative to the headgear at the unfused region.

The overlapping panels define a fused region where they are fused together, and the headgear has reduced extensibility at the fused region relative to each of the first and second panels.

The overlap panel is fused together to define a fused region, and the headgear has reduced extensibility at the fused region relative to the headgear at the non-overlap region.

The overlap region includes a plurality of discrete regions of the overlap panel.

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

The headgear has different material properties or characteristics selected from one or more of drape, stretch properties, density, surface hardness, surface texture, and thickness at each of:

a) The fused portion of the panel is overlapped,

b) Non-fused portion of overlapping panels

c) The non-overlapping region of the first panel.

The headgear includes one or more of greater stiffness, reduced extensibility, less thickness, and smoother surface texture at the fused portion than the headgear at the unfused portion.

The non-overlapping region of the first panel is a first non-overlapping region, and the headgear further includes a second non-overlapping region at which the second panel does not overlap.

The headgear includes different stretch characteristics at each of the following:

the fused portion of the overlap region,

non-fused portion of overlap region

The non-overlapping region of the first panel.

The adjacent surfaces of the first and second panels are fused together around the perimeter of the overlap region.

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

The adjacent surfaces of the first and second panels are fused together around the entire perimeter of the overlap region.

The second panel is fully overlapped with the first panel such that an area of the second panel defines an overlap region.

The second panel is fully overlapped with the first panel and adjacent surfaces of the first and second panels are fused together around the entire perimeter of the second panel.

The perimeter of the second panel is a boundary within the perimeter of the overlap region.

Fusion is applied to the panels on the boundaries of both sides of the perimeter of the second panel.

The perimeter of the overlap region is a boundary within the perimeter of the overlap region.

The perimeter of the overlap region includes boundaries on both sides of the perimeter of the overlap region.

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

The width of the border is about 2mm to about 10mm.

The boundary extends at least about 2mm beyond the overlap region.

The amount by which the boundary extends beyond the overlap region is at least equal to a predetermined panel placement tolerance during manufacture.

Heating is performed on the border such that the first panel and the second panel at the overlap region of the border and the or each panel at the non-overlap region of the border are affected by the heating.

The heating fuses the first and second panels together at the overlap region of the boundary.

When the panel is heated, the material properties of the panel are altered relative to a panel that is not exposed to heating.

Heating includes melting the material of one or both of the panels.

The first panel and the second panel are continuously fused together across the overlap region at the overlap region between two or more points around the perimeter of the overlap region or around the perimeter of the overlap region.

wherein the overlap region and the non-overlap region together comprise at least one first region of extensibility and at least one second region of relatively reduced extensibility, an

Wherein each of the at least one second stretch zone is defined by a fused portion of the overlap region and each of the at least one first stretch zone is defined by a non-fused portion of one or both of the overlap region and the non-overlap region.

The fused portion of the overlap region is less stretchable than the unfused portion of the overlap region.

The fused portion of the non-overlap region is less stretchable than the non-fused portion of the non-overlap region.

The headgear is more stretchable in the first stretch zone than the headgear is in the second stretch zone.

The headgear is substantially inextensible at the second stretch zone.

The first layer is an extensible layer and the second layer is a relatively less extensible layer.

Each of the overlap region and the non-overlap region includes each of an extension region and a non-extension region.

According to another aspect, the present disclosure provides a headgear for a patient interface having a central section including a first layer and a second layer and defining at least one stretch zone in which the first layer does not overlap the second layer and at least one stretch reduction zone in which the first layer overlaps the second layer,

wherein the stretch zone is located between laterally spaced lacing connection portions of the central segment.

The central section includes a reduced extensibility region at an upper portion thereof, and the reduced extensibility region is connected to lateral sections of the headgear on either side of the central section.

The one or more reduced extensibility regions of the central section and the lateral sections define a zone of the headgear.

The region of reduced extensibility extends beyond the boundary where the first layer overlaps the second layer.

One or more layers of the headgear at one or more regions of reduced extensibility are welded.

The headgear further includes one or more overlap stretch regions in which the first layer overlaps the second layer, and wherein the headgear is unwelded at each of the one or more overlap stretch regions.

The lateral extent of each lateral region defines one or more lacing connection portions.

Each of the one or more lacing connection portions has an increased width relative to a portion of the zone at each respective lateral region.

The one or more lace connection portions each include at least one of the one or more overlapping extensibility-reducing areas.

The headgear has a lateral dimension along the zone and a width dimension perpendicular to the zone, and the second layer is about 60% to about 95% of the width of the first layer at one or both of the lateral sections.

At one or both of the lateral sections, the second layer is about 70% to about 80% of the width of the first layer.

At one or both of the lateral sections, the second layer is about 80% to about 90% of the width of the first layer.

The headgear has a lateral dimension along the zone and a width dimension perpendicular to the zone, and the second layer is about 20% to about 70% of the width of the first layer at a lateral middle of the stretch zone.

The second layer is about 40% to about 60% of the width of the first layer at the lateral middle of the stretch zone.

One or more of the one or more strap connecting portions taper laterally away from the strap.

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

The one or more strap attachment portions include a strap, and the strap attachment portion and strap are contained by the panel of extensibility and/or the panel of relatively reduced extensibility.

The central section has an extended region between the zone and the two lacing connection portions.

The overlap region is continuous.

The non-overlap region is continuous.

The first layer has a first extensibility value and the second material has a second, smaller extensibility value.

The first layer is an extensible layer and the second layer is a layer of relatively reduced extensibility.

The first layer is an extensible layer and the second layer is a non-extensible layer.

According to another aspect, the present disclosure provides a headgear for a patient interface, wherein the headgear has a strap portion and a plurality of strap connection portions and includes a plurality of overlapping panels defining at least one overlapping region in which at least two panels of the plurality of panels overlap and overlap each other, respectively, and at least one non-overlapping region in which one or more of the plurality of panels does not overlap another of the plurality of panels,

wherein the headgear is welded at each of the at least one overlap region to fuse adjacent surfaces of the overlap panels together, an

a) The zone portion having a first arrangement of welded adjacent panel surfaces and unwelded adjacent panel surfaces of one or more overlap regions within the zone, and

b) One or more of the plurality of lacing connection portions has a second arrangement of welded adjacent panel surfaces and unwelded adjacent panel surfaces of one or more overlap regions within the or each respective one or more of the plurality of lacing connections, the second arrangement being different from the first arrangement.

The first arrangement includes adjacent panel surfaces that are substantially completely welded.

For example, adjacent panel surfaces may be welded to each other except for portions of the smaller interior region of the headgear.

Adjacent panel surfaces may be welded to each other except for portions defining the desired surface texture.

The second arrangement includes a welded adjacent panel surface having one or more non-welded areas.

The one or more non-welded areas are located within a line of demarcation with an edge of any overlap area within one or more of the plurality of strap connection portions.

The dividing line is at least 2mm.

The dividing line is about 2mm to about 10mm.

The one or more non-welding zones further include one or more welds to limit the spacing of the overlapping panels within the or each of the one or more non-welding zones.

The welding region of the headgear extends beyond the perimeter of each of the at least one overlap region.

The welding region of the headgear includes a border region adjacent to any non-overlapping region of the overlapping region.

The width of the border is about 2mm to about 10mm.

The boundary extends at least about 2mm beyond the overlap region.

The welded portion of the overlap region includes different material properties than the non-welded portion of the same overlap region.

The welded portion of the non-overlapping region includes different material properties than the non-welded portion of the same non-overlapping region.

The headgear further includes a plurality of straps corresponding to the plurality of strap connection portions, and each strap of the plurality of straps is contained by one or more of the plurality of strap panels.

The headgear further includes a plurality of straps, one strap for connection to each of the plurality of strap connection portions.

The plurality of panels includes a first panel and a second panel that is fully overlapped with the first panel, the first panel and the second panel defining an overlap region and at least one non-overlap region of the first panel, and wherein the overlap region includes each of: a zone, and at least two of the plurality of strap connection portions.

Each of the plurality of strap attachment portions depends from the zone.

At least one pair of strap attachment portions extends laterally toward the zone from the location where the strap is to be attached.

The zone further includes one or a pair of top ties.

According to another aspect, the present disclosure provides a headgear for a patient interface, the headgear comprising first and second stretchable materials in respective panels that at least partially overlap each other,

Wherein the overlapping panels of the first and second stretchable materials are joined together at a joining region such that they have low stretch.

The first stretchable material is more stretchable than the second stretchable material.

At the junction region, the headgear has less extensibility than either the first extensible material alone or the second extensible material alone.

At the joined regions, the headgear has less extensibility than the overlapping first and second extensible materials at the non-joined regions.

The low stretch where the lap panels are joined together is a relatively lower stretch than where the lap panels are not joined together.

At the bonded regions, the headgear has reduced stretch relative to the non-bonded regions.

At the attachment region, the headgear is substantially inextensible.

The overlapping panels of the first and second stretchable materials are joined together at a joining region by fusing the panels together.

The overlapping panels of the first and second stretchable materials are joined together at a joining region by fusion via melting of one of the materials into the other.

Providing first and second panels defining a lap zone in which the first and second panels overlap and overlap each other, respectively, and a non-lap zone in which the first panel is not overlapped, and

one or both of the panels are melted at the overlap region to fuse the panels together and define a fused region of the overlap region.

The method further includes the step of melting the first panel at the non-overlap region to define a fused region of the non-overlap region.

The first panel is melted to define a fused region around the perimeter of the overlap region.

The step of melting one or both of the panels at the overlap region and melting the first panel at the non-overlap region is provided as a single operation.

The one or more melting steps include applying heat and pressure to the first panel and/or the second panel.

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

The first melting point is higher than the second melting point.

The one or more melting steps include increasing the temperature of at least a portion of the first and second panels to a temperature above the second melting point but below the first melting point.

The one or more melting steps include applying heat and pressure to both the first panel and the second panel, but only the second panel is melted.

The one or more melting steps include welding.

The first panel and the second panel are disposed between the first mold and the second mold.

The method further comprises the step of moving the first mold and the second mold towards each other.

The step of moving the first mold and the second mold toward each other is contained by the one or more melts.

The first mold includes a first relatively convex horizontal surface and a second relatively concave horizontal surface, wherein the first horizontal surface defines one or more fused regions and the second horizontal surface defines an unfused region where one or more panels of the headgear do not melt.

The first mold includes a substantially direct transition between the first level and the second level.

The first mold includes a graded transition between the first level and the second level.

The graded transition of the first mold defines a transition zone between a fused zone and an unfused zone of the headgear.

The level of the graded transition of the first mold varies linearly between the first level and the second level.

The level of the graded transition of the first mold follows an s-curve shape.

The first level and the second level define indicia in relief such that when melted, the headgear includes one or more fused regions and unfused regions representing the indicia.

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

One or both of the dies includes a cutting element and the step of cutting is combined with the step of moving the first die and the second die towards each other.

The step of melting one or both of the panels at the overlap region occurs after bringing the two molds together with the first and second panels therebetween.

The step of melting the first panel at the non-overlap region occurs after bringing the two molds together with the first and second panels therebetween.

The first panel is more stretchable than the second panel.

One of the first and second panels has a higher melting point than the other of the first and second panels.

According to another aspect, the present disclosure provides a rear portion of a headgear comprising a first overlapping panel and a second overlapping panel, the overlapping panels defining an overlapping region in which the first panel and the second panel overlap and overlap, respectively, and a non-overlapping region in which the first panel is not overlapped,

The lateral ends of the overlap region remain unfused to receive the headgear strap between the first panel and the second panel.

According to another aspect, the present disclosure provides a headgear comprising a rear portion and a pair of straps, each strap sandwiched between a first panel and a second panel at lateral ends of a lap region.

The overlapping first panel, second panel, and lacing are fused together at each lateral end of the overlap region.

According to another aspect, the present disclosure provides a headgear comprising a plurality of panels, wherein at least a portion of each panel overlaps at least a portion of the other panel, the panels being joined together to provide a thin and seamless or substantially seamless headgear.

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

According to another aspect, the present disclosure provides a headgear comprising a plurality of panels, wherein at least a portion of each panel overlaps at least a portion of the other panel, the panels being fused together to provide a lightweight headgear.

According to another aspect, the present disclosure provides a headgear comprising a plurality of panels, wherein at least a portion of each panel overlaps at least a portion of the other panel, the panels being fused together, wherein the panels are configured such that the headgear retains at least to some extent its shape in use when in an idle state.

At least one of the plurality of panels comprises a different material than another panel of the plurality of panels.

At least one of the panels comprises a different material at the overlap region than the other panel at the overlap region.

The plurality of panels includes a first panel and a second panel, and the first panel includes a material different from a material of the second panel.

The plurality of panels further includes a third panel, and the second panel and the third panel include the same material that is different from the material of the first panel.

The different materials include one or more of the following: different textures, softness, stretch properties (including one or more of in-plane stiffness, out-of-plane flexibility, and restorability), density, thickness, color, coefficient of friction with respect to a reference material, breathability, or transparency.

The different materials include one or more of the following, which are directionally different: texture, softness, stretch properties (including one or more of in-plane stiffness, out-of-plane flexibility, and restorability), or coefficient of friction relative to a reference material.

The two opposite major faces of at least one of the plurality of panels include one or more of: different textures, coefficients of friction or colors of the opposite major faces of the panel.

The exposed portions of the major faces of the plurality of panels define an inner surface and an outer surface of the headgear that in use is opposite the head of the patient, and wherein at least some of the plurality of panels each define a portion of the inner surface and/or the outer surface of the headgear.

The at least some of the plurality of panels include one or more of: different textures, softness, color, or coefficient of friction relative to a reference material.

At least some of the panels defining a portion of the interior surface of the headgear include greater surface softness than at least some of the panels defining a portion of the exterior surface of the headgear.

Only some of the plurality of panels define an inner surface and only some of the plurality of panels define an outer surface.

Excluding the or each of the at least one non-overlapping region, the exposed portion of the panel defines a portion of one or the other of the inner and outer surfaces.

The plurality of panels includes a first panel of stretchable material and a second panel of stretchable material, wherein the first stretchable material and the second stretchable material differ in extensibility.

The plurality of panels includes at least one elasticized textile panel and at least one non-elasticized textile panel.

The plurality of panels includes:

a posterior portion for positioning at a posterior portion of a patient's head;

top lacing

At least two side straps for attachment to the patient interface.

The rear portion transfers load between the at least two side straps, and the rear portion includes at least one first material panel that overlaps a portion of the side strap panel of each of the at least two side straps.

The rear portion includes a plurality of first material panels, and each of the at least two side ties overlaps the first material panels on a respective side.

The lowermost extent of the rear portion on the rear of the user's head includes a lower panel of a second material.

The second material is a non-dispersible material.

The lower panel overlaps or is overlapped with one or more panels of the plurality of first material panels.

The lower panel of the second material is more stretchable than the plurality of panels of the first material.

The lower panel of the first material is an extensible panel and the plurality of panels of the first material are non-extensible panels.

The lower panel of the second material is elasticized and the plurality of first material panels are inelastic.

The lower panel of the second material has a greater elasticity than the plurality of panels of the first material.

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

A portion of the lower panel is in a non-overlapping region of the headgear and the portion of the lower panel is generally crescent-shaped.

At least a portion of the lower panel in the non-overlapping region of the headgear is generally crescent-shaped, i.e., has a concave edge and a convex edge, and wherein the concave edge forms at least a portion of the lower peripheral edge of the rear portion.

The rear portion includes an upper edge panel forming at least a portion of an upper peripheral edge of the rear portion, the upper edge panel comprising a thinner and/or softer material than the panel to which it is overlapped.

The upper edge panel overlaps the other panel at the rear portion to define an inner surface of the headgear at an upper region of the rear portion, in use, relative to the patient's head.

The upper edge panel is disposed within the overlap region and the non-overlap region, and wherein the non-overlap region forms at least a portion of an upper peripheral edge of the rear portion.

The upper edge panel is configured at the non-overlap region to roll up away from the patient's head in use and toward the upper peripheral edge of the rear portion.

The upper edge panel extends away from the adjacent overlap region at the non-overlap region a distance from about 5 to about 20 times the thickness of the upper edge panel.

The top strap defines an inner surface that is oriented toward the patient's head in use and an outer surface that is oriented away from the patient's head in use, and wherein the inner surface has a greater softness than the outer surface.

The top strap depends from the rear portion.

The top strap depends from the rear portion and at least one of the side straps and/or the top strap of each lateral side of the rear portion.

The width of the top strap is greater than the width of at least two side straps.

The top strap is a different color than the at least two side straps.

The top strap includes a pair of top strap portions adjustably secured to one another to provide a variable length top strap, each top strap portion including a top strap portion inner panel and a top strap portion outer panel adhesively bonded to one another.

The top strap portion inner panel has greater softness than the top strap portion outer panel.

The top strap portion inner panel and top strap portion outer panel overlap and overlap, respectively, one or more rear and/or side strap panels to which they overlap.

The top strap is relatively more rigid and/or dense than the rear portion.

The top strap includes one or more panels of a material that is more rigid and/or more dense than the one or more panels that make up the rear portion.

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

The two upper straps include an integral panel that extends over the rear portion of the headgear.

The unitary panel is disposed within an overlap region spanning at least a portion of the rear portion of the headgear and within a pair of distal non-overlap regions.

The upper and lower straps include integral panels configured to extend around the rear of the patient's ears.

The overlapping areas of the upper lacing overlap and overlap the panels of the top lacing, respectively.

The lower lacing overlaps and overlaps the plurality of panels of the rear portion.

An ear loop for passing behind the patient's ear defines a lateral peripheral edge of the posterior portion between the upper and lower lateral tethers of each lateral group.

The edge profile of each ear loop includes a pair of straight portions.

The pair of straight portions form a V-shape, with the tip of each V pointing toward the other tip and into the rear portion of the headgear.

The two upper straps include two respective panels, each panel disposed in an overlap region at the rear of the headgear and in a distal non-overlap region.

Each of the two corresponding panels of the two upper straps overlap and overlap with the panel of the rear portion of the headgear.

The terminating portion of one or both of the upper and lower tethers includes a gripping tab that includes a first tab panel and a second tab panel that overlap and overlap the terminating portion at a first tab region and overlap each other at a second tab region further to the side, respectively.

The material of the first and second tab panels has one or more of the following compared to the material of the corresponding tie in the upper and lower tie sets: thinner, softer, a different color, or a lower coefficient of friction relative to a reference material.

The first and second tab panels are plastic material having one or more of the following compared to the material of the respective tie in the upper and lower tie sets: thinner, stiffer, different colors, or lower coefficient of friction relative to the reference material.

The headgear has a greater stiffness at the second, more distal tab region than the headgear at the first tab region.

The second more distal tab region is thinner than the one or more upper and lower side ties at the non-overlapping region.

The grip tab further includes a first half of a hook and loop fastener at one outer surface.

The side straps are configured such that when the straps are folded back on themselves, the strap surface corresponding to the first half of the hook-and-loop fastener comprises the second half of the hook-and-loop fastener.

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

Each of the side strap sets is configured to be folded back upon itself and attached to itself to define a connecting loop through which the patient interface may be retained.

Each of the side straps of the side strap set includes a series of visual features along at least one surface of the side strap that are used to indicate an adjustment point to the patient when the side strap is folded back upon itself.

These visual features are regularly spaced along the surface of each side tie.

Each of the side straps of the side strap set includes a series of tactile features along at least one surface of the side strap for providing tactile feedback to the patient regarding different adjustment conditions of the respective strap.

The series of tactile features provides a guide for adjustment of each respective side strap.

The interaction of the tactile features with the patient interface provides tactile feedback to the patient.

Each side strap includes a strap panel that overlaps the haptic feedback panel on at least one major face, wherein the haptic feedback panel has one or more of a thinner, stiffer, and more rigid than the strap panel with which it overlaps, and wherein the haptic feedback panel and the strap panel are fused together.

The haptic feedback panel includes haptic features that are provided by a series of voids through the haptic feedback panel.

This series of voids presents the haptic feedback panel as having a series of ridges relative to the lacing panel that it overlaps.

The tactile feedback panel is stiffer and/or more rigid than the harness panel, and the series of ridges are for mechanically engaging with a buckle of the patient interface.

Each respective lateral extent of the top strap and the rear portion are non-overlapping butted against each other and with an end of a respective one of the side straps.

Each respective lateral extent of the top strap and the rear portion interfaces with an end of the respective side strap in an edge-to-edge configuration.

Each respective lateral extent of the top strap and the rear portion overlaps the end of the respective side strap with the connector panel on at least one set of major faces.

At least one major face of one or more of the top strap, the rear portion, and the side strap overlaps the reinforcement panel along at least a portion toward a periphery thereof.

The reinforcement panel includes a less stretchable material than a corresponding one or more of the top strap, the rear portion, and the side straps.

The reinforcement panel comprises a material having a relatively reduced extensibility.

The reinforcement panel comprises a low stretch material.

The reinforcement panel includes a non-stretchable material.

The reinforcement panel comprises a substantially inextensible material.

The reinforcement panel comprises a non-elasticized material.

The top strap comprises a single integral strap.

The rear portion includes a single integral strap.

The top strap and the rear portion include a closed loop.

The side strap sets depend from the intersection of the top strap and the rear portion.

In use, the intersection of the top strap and the rear portion is above the patient's ear.

One or more of the side strap sets, the rear portion, and the top strap at least partially include a first stretchable panel that overlaps and overlaps a pair of second stretchable panels, wherein the first stretchable panel is more stretchable than the second stretchable panel.

One or more of the side strap sets, the rear portion, and the top strap at least partially include a relatively elastic panel that overlaps and overlaps a corresponding relatively inelastic panel.

The entirety of one or both of the top strap and the rear portion includes a first stretchable panel that overlaps and overlaps a pair of second stretchable panels, wherein the first stretchable panel is more stretchable than the second stretchable panel.

The entirety of one or both of the top strap and the rear portion includes a relatively elastic panel that overlaps and overlaps a corresponding relatively inelastic panel.

The rear portion and the top strap form a closed loop, and the rear portion and the top strap together comprise a relatively more stretchable panel and a relatively less stretchable panel.

The rear portion and the top strap include two relatively less stretchable panels that each overlap with a relatively more stretchable panel at a respective first end and overlap with each other at the other end.

The rear and overhead portions include a single relatively less stretchable panel that overlaps one or more relatively more stretchable panels at lateral ends.

The material of the first and second tab panels has one or more of the following compared to the material of the corresponding tie in the upper and lower tie sets: thinner, softer, different colors, or lower coefficient of friction.

One or more panels of the plurality of panels comprise a non-dispersible material.

At least a portion of the edge of the headgear is treated with a conditioning agent.

The edge portion treated with the conditioning agent includes increased wear resistance relative to a non-adhesive overlap edge portion of the same material.

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

An adhesive is provided between the rolled portion and the portion that the rolled portion is rolled back.

At least a portion of the edge of the headgear includes an edge-softening panel, a portion of which overlaps a more interior panel, and wherein the edge panel comprises a thinner and/or softer material than the more interior panel it overlaps.

The edge panel overlaps the more interior panel such that the edge panel defines an interior surface of the headgear that is, in use, opposite the patient's head.

The edge panel is configured to roll away from the patient's head in use and towards its outer end.

The distance that the non-overlap region of the edge panel extends away from the adjacent overlap region is from about 5 to about 20 times the thickness of the more interior panel that it overlaps.

The weight of the headgear is less than about 30g.

The weight of the headgear is less than about 20g.

The weight of the headgear is less than about 10g.

The weight of the headgear is from about 15g to about 30g.

The weight of the headgear is from about 17.5g to about 27.5g.

The weight of the headgear is about 25g.

One or more of the plurality of panels comprises a planar panel.

One or more of the plurality of panels comprises a tubular panel.

According to another aspect, the present disclosure provides a headgear comprising a first panel comprising a selectively fused region, wherein in the selectively fused region the first panel is continuously fused along a first direction and is at least partially discontinuously fused along a second direction, the second direction being a different direction than the first direction.

Within the selective fusion zone and in the first direction, all fused portions of the first panel are continuous with each other.

At least some of the fused portions of the first panel are discontinuous with one another within the selectively fused region and in the second direction.

Within the selectively fused region and in the second direction, the fused region is discontinuous.

The headgear includes a second panel that at least partially overlaps the first panel, and the selectively fused region includes at least a portion of the overlapping panel.

At the selectively fused region, the headgear has a reduced extensibility in the first direction relative to the second direction.

The second direction is substantially perpendicular to the first direction.

The selective fusion zone is provided to one or more elongated portions of the headgear, and a first direction is taken transverse to the length of each elongated portion, and a second direction is taken along the length of each elongated portion.

The elongate portion includes a plurality of laces.

The elongate portion includes a rear ring.

The selective fusion zone is disposed at a crotch portion of the headgear, and the second direction is taken across the crotch portion, and the first direction is taken along a respective side of the crotch portion.

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

The headgear includes a first selectively fused region between lateral sides of the rear portion of the headgear, a second selectively fused region and a third selectively fused region each between a respective lower strap connection portion of the rear portion and the first selectively fused region.

The selective fusion zone is configured such that when coupled to the interface, the headgear defines a continuous loop of fusion material from a first side of the interface that surrounds the patient's head to a second side of the interface.

According to another aspect, the present disclosure provides a headgear for a patient interface comprising first and second overlapping panels defining an overlapping region in which the first and second panels overlap and overlap, respectively, one another, and a non-overlapping region in which the first panel is not overlapped, wherein the panels are fused together at the overlapping region, and wherein the width of the non-overlapping region varies.

The non-overlap region is relatively more stretchable than the overlap region.

The first panel is an extensible panel and the second panel is a non-extensible or relatively reduced extensibility panel.

The headgear includes one or more zones of extensibility and the width of the non-overlapping region locally increases at the or each zone of extensibility.

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

The maximum width of the non-overlapping region at the ear loop of the headgear is located at the region above and behind the patient's ear in use.

At the ear loop, the ratio of the total width of the one or more non-overlapping regions to the overlapping region is from about 1:1 to about 3:1.

The non-overlapping region has a substantially constant width at an upper side of the rear portion of the headgear and the non-overlapping region varies in width at a lower side of the rear portion of the headgear.

According to another aspect, the present disclosure provides a headgear for a patient interface comprising first and second overlapping panels defining an overlapping region in which the first and second panels overlap and overlap each other, respectively, wherein a filament is disposed between the first and second panels at the overlapping region, and the panels are fused together on each side of the filament.

The wire can be pulled between the panels.

The wire extends around the loop of the headgear between the two patient interface connection ends of the headgear, and the wire can be pulled between the panels to adjust the fit of the headgear.

According to another aspect, the present disclosure provides a headgear for a patient interface having three stiffening structures at each side of the headgear:

a) A first stiffening structure for providing stiffness between the rear portion of the headgear and the top strap,

b) A second reinforcing structure for providing rigidity between the top strap and the upper strap of the headgear, and

c) A third stiffening structure for providing stiffness between the rear portion of the headgear and the lower strap,

wherein the three reinforcing structures are formed by fusing the headgear at each respective location.

The headgear includes a first panel and the fusing of the headgear includes fusing of the first panel.

The headgear further includes a second panel that at least partially overlaps the first panel, and the fusing at least partially includes fusing the overlapping first and second panels.

The one or more panels comprise a textile comprising a polymeric material, and the one or more panels form a solid plastic when fused.

The three reinforcing structures are formed by fusion of the one or more panels, excluding any additional components provided to the one or more panels.

The three reinforcing structures are continuous with each other.

According to another aspect, the present disclosure provides a headgear for a patient interface comprising a rear portion having a first strap panel and a second strap panel, and at least two straps, wherein each of the at least two straps is fused to only the first panel of the rear portion.

The second panel does not overlap any of the at least two tethers.

According to another aspect, the present disclosure provides a headgear for a patient interface comprising a rear portion having a first strap panel and a second strap panel, and a plurality of straps that are strap-bonded and fused to the rear portion, wherein portions of each of the straps that are not strap-bonded to the rear portion are straight.

The non-overlapping portion of each strap and the portion that is not overlapped to the rear portion have a constant width.

The portions of each strap that overlap and do not overlap the rear portion are straight and/or have a constant width.

According to another aspect, the present disclosure provides a headgear for a patient interface, the headgear comprising:

having a rear portion of the first and second landing panels,

at least one slot cut into the second panel, and

at least one strap, each strap having a strap end inserted through a respective slot to be positioned between the overlapping first and second panels,

wherein each of the at least one strap and the rear portion are joined by fusion of the first and second panels and each of the at least one strap ends.

Having a rear portion of the first and second landing panels,

at least one slot cut into the second panel, and

at least one strap, each strap having a strap end inserted through a respective slot and folded back upon itself.

Each of the at least one strap is joined to the rear portion by fusing to itself at the folded-back portion.

Each of the at least one strap is joined to the rear portion by releasable connection of the strap to itself at the return portion.

The at least one slot is cut through both the first panel and the second panel.

rear portion having a first overlap panel and a second overlap panel, and

a top tie having a thinned central region, the top tie being sandwiched between the first and second overlapping panels of the rear portion,

wherein the rear portion and the top strap are joined together by fusion.

The top strap has a straight shape prior to being coupled to the headgear.

The top strap has a curved shape when sandwiched between the first panel and the second panel.

Having a rear portion of the first and second landing panels,

a plurality of laces, an

A tie material layer overlying the overlapping first and second panels, wherein the tie material layer comprises the same material as each of the plurality of ties, and the plurality of ties each overlap the tie material layer and are fused to the tie material layer.

The headgear includes a plurality of layers of strapping material, each layer of strapping material overlying the overlapping first and second panels and having at least one strap overlapped and fused thereto.

The one or more tie material layers overlap only the second panel of the rear portion.

having a rear portion of the first and second landing panels,

a top lacing panel partially overlapping the rear portion, the top lacing panel including a slot, and

a tie that extends through the slot and is secured back to itself.

The headgear has left and right top strap panels that each partially overlap on respective left and right sides of the rear portion, and each top strap panel includes a slot through which a respective strap extends and is secured back onto itself.

having a rear portion of the first and second landing panels,

two laces, and

two overmolded components, wherein each of the overmolded components is overmolded onto a respective one of the two straps to secure the rear portion and the straps together.

The rear portion includes two slots through the rear portion, and the overmolded components each further include a mounting post having a base and a head, wherein the heads of the respective mounting posts are inserted through each respective slot to connect the rear portion and the overmolded components together.

Each head includes lateral wings that are wider than the corresponding slots.

The headgear includes four straps, and two straps are overmolded by each of the overmolded components.

The rear portion includes two slots through the rear portion, and respective portions of each of the overmolded components are fused to one another by each respective slot.

a rear portion having a first landing panel and a second landing panel and defining a lacing connection region, an

A tie positioned at the tie connection area,

wherein the rear portion is folded over the lace at the lace connection region.

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

According to another aspect, the present disclosure provides a rear portion of or for a headgear, the rear portion for connection to a patient interface, the rear portion comprising first and second overlapping panels defining an overlapping region, and wherein the entire perimeter of the overlapping regions of the first and second overlapping panels are fused together except at one or more strap connection regions.

The headgear is formed by inserting a portion of the strap between the first and second overlapping panels at each strap connection region and fusing the panels and strap together.

The first panel and the second panel are fused together around the entire perimeter of the overlapping region of the headgear.

According to another aspect, the present disclosure provides a rear portion of or for a headgear, the rear portion for connection to a patient interface, the rear portion comprising a first overlapping panel and a second overlapping panel defining an overlapping region, wherein the entire perimeter of the overlapping portions of the first panel and the second panel are fused together except at one or more strap connection regions.

The first and second landing panels are fused together around the entire perimeter of the landing zone.

The first panel and the second panel are completely fused together at the overlap region of the headgear.

According to another aspect, the present disclosure provides a headgear comprising a first overlapping panel and a second overlapping panel, the overlapping panels defining an overlapping region in which the first panel and the second panel overlap and overlap, respectively, wherein the overlapping panels are fused together such that a linear condition is satisfied between two edges of the overlapping region, wherein a total length of a line between a selected two edges of the fusion along the overlapping region exceeds a total length between two edges of the fusion according to the linear condition.

A straight line condition is satisfied between at least a pair of corresponding upper and lower edges of the overlapping region of the rear portion of the headgear.

Any straight line between the upper and lower edges along the overlap region of the rear portion of the headgear satisfies the straight line condition.

Any line between the two edges along the overlap region of the rear portion of the headgear satisfies a straight line condition.

The headgear further defines a non-overlapping region where the first panel is not overlapped.

Along the line between the edges of the overlap region, the fused portions are located at both ends of the line.

Along the line between the edges of the overlap region, the non-fused portions are located only away from the two ends of the line.

Along the line between the edges of the overlap region, the cumulative length along the line at both ends of the line where the overlap is fused exceeds the cumulative length along the line where the overlap is unfused.

Along the line between the edges of the overlap region, the cumulative length along the line at both ends of the line where the overlap is fused exceeds the cumulative length along the line at the central portion where the overlap is not fused.

While headgear is generally mentioned in the context of a patient, it should be understood that the term "patient" may be replaced with an assistant or medical professional of the patient, as appropriate, or any other person likely to use or interact with the headgear (whether for self use or in connection with helping others use the headgear).

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

As used herein, the term "preceding a noun" refers to the plural and/or singular forms of the noun.

For the purposes of this specification, the term "plastic" should be interpreted as a generic term referring to a broad range of synthetic or semi-synthetic polymeric products and is generally composed of hydrocarbon-based polymers.

For the purposes of this specification, where method steps are described in a sequential order, that order does not necessarily imply that the steps will be ordered in time by this order, unless there is no other logical way of interpreting the order.

The term "comprising" as used in the present specification and claims means "consisting at least in part of the following. When interpreting each statement in this specification that includes the term "comprising," features other than that or those that follow the term are also possible. The relative terms "comprising" and "including" will be interpreted in the same manner.

Other aspects of the invention will become apparent from the following description, given by way of example only, and with reference to the accompanying drawings.

Drawings

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1A and 1B are cross-sectional views of a pre-fusion configuration and a fusion configuration of two panels, respectively.

Fig. 2A and 2B are cross-sectional views of another pre-fusion and fusion configuration of two panels.

Fig. 3A and 3B are cross-sectional views of another pre-fusion and fusion configuration of two panels.

Fig. 4A and 4B are cross-sectional views of a pre-fusion configuration and a fusion configuration of three panels.

Fig. 5A and 5B are a front cross-sectional view and a rear cross-sectional view of two panels.

Fig. 6A is a cross-sectional view of a pre-fusion configuration of three panels.

Fig. 6B and 6C illustrate two different fusion configurations of the three panels of fig. 6A.

Fig. 7A is a plan view of two panels overlapping each other.

Fig. 7B shows the area around the perimeter of the overlap of the two panels of fig. 7A, where the two panels are to be joined together.

Fig. 7C shows the assembly of fig. 7B, but wherein the panel and the joining region are relatively misaligned.

Fig. 8A is a plan view of two panels overlapping each other.

Fig. 8B shows an area spanning the overlap of the two panels of fig. 7A, where the two panels are to be joined together.

Fig. 8C shows the assembly of fig. 7B, but wherein the panel and the joining region are relatively misaligned.

Fig. 9A is a side view of a press welder for welding headgear, wherein the press welder is open.

Fig. 9B is a side view of a press welder for welding a headgear, wherein the press welder is closed.

Fig. 10 is a view of a headgear that retains an interface to a patient's face.

Fig. 11 is a flat-down view of the headgear.

Fig. 12 is a view of two panels.

Fig. 13 is a view of the two panels of fig. 12 overlapping each other to define a portion of a headgear.

Fig. 14 is a view of the headgear of fig. 13, wherein the panels have been fused together.

Fig. 15 is a view of a headgear showing a line of demarcation within which fusion may be applied to a face plate of the headgear.

Fig. 16 is a close-up view of a portion of the headgear of fig. 14, showing two overlapping panels and a line of demarcation to which fusion is applied.

Fig. 17A is a flat-laid view of the headgear.

Fig. 17B is a flat-laid view of the headgear of fig. 17A with straps attached thereto.

Fig. 18 is a flat-down view of the headgear.

Fig. 18-1 is a flat-down view of the headgear.

Fig. 18-2 is a view of the headgear of fig. 18-1 worn by a patient.

Fig. 18-3 are views of four different rear portions for a headgear.

Fig. 19 is a flat-down view of the headgear.

Fig. 20 is a view of a mold forming the headgear of fig. 19.

Fig. 21 is a flat-down view of the headgear.

Fig. 22 is a view of a mold forming the headgear of fig. 21.

Fig. 23 is a flat-down view of the headgear.

Fig. 24 is a view of a mold forming the headgear of fig. 23.

Fig. 25 is a view of another configuration of a mold with a mark forming element.

Fig. 26 is a view of a portion of a headgear with indicia formed therein.

Fig. 26-1A is a view of a headgear and patient interface.

Fig. 26-1B is a cross-sectional view through line A-A of fig. 26-1A.

Fig. 27 is a flat-laid view of a headgear with indicia formed therein.

Fig. 28A is a pre-fusion flat view of the headgear.

Fig. 28B is a view of the headgear of fig. 28A after it has been fused.

Fig. 29 is a flat-down view of the headgear.

Fig. 30 is a flat-down view of the headgear.

Fig. 31 is a flat-down view of the headgear.

Fig. 32 is a flat-down view of the headgear.

Fig. 33 is a flat-down view of the headgear.

Fig. 34 is a flat-down view of the headgear.

Fig. 35 is a view of the headgear in a hanging configuration when held by a patient.

Fig. 36A and 36B are views of a headgear on a patient's head.

Fig. 37A is a panel for a portion of a strap.

Fig. 37B shows the panel of fig. 37A coupled to another lacing panel.

Fig. 38 shows another lacing panel.

Figures 39A and 39B are top and side views, respectively, of the lace end features.

Fig. 40A and 40B are flat-laid views of a headgear having a stamped portion.

Fig. 40C is a view of a rear portion of a headgear having a stamped portion.

Fig. 41 is a partial view of two configurations of headgear.

Fig. 42 is a view of a continuous fusion process for forming a portion of a headgear.

Fig. 43 is a view of another continuous fusion process for forming a portion of a headgear.

Fig. 44 is a view of another continuous fusion process for forming a portion of a headgear.

Fig. 45 is a view of another continuous fusing process for forming a portion of a headgear, wherein the headgear portion is stretched before it is fused.

Fig. 46-1A is a view of a headgear panel and two inserts.

Fig. 46-1B is a view of two fused panels with a pocket formed therebetween.

Fig. 46-2 is a view of two fused panels with a void formed therebetween.

Fig. 46-3 is a view of two fused panels with a continuous pocket formed therebetween.

Fig. 47A is a view of a headgear and interface, wherein the fused headgear panel defines an air duct.

Fig. 47B is a cross-sectional view of the air duct through line A-A of fig. 47A.

Fig. 48A-48D are views of steps in a process for attaching a strap to another portion of a headgear.

Fig. 49A is a view of a panel, and fig. 49B-49D are views of an illustrative fusion pattern that may be applied to the panel of fig. 49A.

Fig. 50 is a view of a portion of a headgear.

Fig. 51 is a view of a portion of a headgear.

Fig. 52 is a view of the rear portion of the headgear.

Fig. 53 is a view of another rear portion of the headgear.

Fig. 54 is a view of the rear portion of the headgear when worn by a patient.

Fig. 55A is a view of a fusion arrangement provided to a panel, and fig. 55B and 55C illustrate the performance of the fused panel under different load conditions.

Fig. 56A is a view of a panel that has been pre-stretched and fused, and fig. 56B is a view of the fused panel of fig. 56A when the pre-stretch is released.

Fig. 57 is a view of the headgear and interface when worn by a patient.

Fig. 58 is a view of the headgear and interface when worn by a patient.

Fig. 59 is a view of the headgear and interface.

Fig. 60A is a view of a headgear and interface with an integral adjustment securement arrangement for the harness strap.

Fig. 60B is a partial cross-section through line A-A of fig. 60A.

Fig. 61A is a view of a lace with an integrated fastening device.

Fig. 61B is a view of a securing device and panel that form the tie of fig. 61A prior to joining the components together.

Fig. 62 is a view of another fixation device.

Fig. 63 is a view of two overlapping panels configured to provide a smooth edge.

Fig. 64 is another view of two overlapping panels configured to provide a smooth edge.

Fig. 65 is a view of two overlapping panels configured to provide smooth edges to both sides of the panels.

FIG. 66 is a view of two overlapping panels configured to provide smooth edges to both sides of the panels.

Fig. 67 is a view of two overlapping panels configured to provide smooth edges to both sides of the panels.

Fig. 68A is a view of a headgear and interface.

Fig. 68B is a cross-sectional view through line A-A of fig. 68A.

Fig. 69A and 69B are views of a process for forming slider features.

FIG. 69C is a view of a panel having the slider feature of FIG. 69B with another panel folded about its edge to smooth the edge.

Fig. 70A is a view of a panel with fused adjustment features formed therein.

Fig. 70B is a cross-sectional view taken along the length of the panel of fig. 70A.

Fig. 71 is a view of a panel with fused adjustment features formed therein.

Fig. 72A is a view of a headgear and interface.

Fig. 72B is a cross-sectional view through line A-A of fig. 72A.

Fig. 72C is a schematic view of a continuous process for forming a headgear portion having filaments therein.

Fig. 72D is a view of two fused panels with filaments slidable therebetween.

Fig. 73 is a view of a headgear that can be adjusted by pulling on a wire disposed within a portion of the headgear.

Fig. 74 is a flat-down view of the headgear.

Fig. 75 is a flat-down view of the headgear.

Fig. 76 is a flat-down view of the headgear.

Fig. 77A is a flat view of the headgear.

Fig. 77B is a partial view of a headgear (such as the headgear of fig. 77A) showing the connection of the strap to the rear portion of the headgear.

Fig. 78 is a flat-down view of the headgear.

Fig. 79A is a flat-laid view of a top strap for a headgear.

Fig. 79B is a flat-down view of a headgear including the top strap of fig. 79A.

Fig. 80 is a flat-down view of the headgear.

Fig. 81 is a flat-down view of the headgear.

Fig. 82A is a partially preassembled view of two straps and a rear portion of a headgear with an overmolded component.

Fig. 82B is a flat view of the headgear.

Fig. 83A is a partially preassembled view of the harness strap and rear portion of the headgear.

Fig. 83B is an assembled view of the lace and rear portions of fig. 83A.

Detailed Description

Various embodiments of headgear for a respiratory interface are described herein. Such headgear may include a plurality of panels configured such that the headgear has at least one overlap region (in which at least two of the plurality of panels overlap and overlap each other) and at least one non-overlap region (in which one or more of the panels do not overlap with another panel). The panels may be joined together at one or more overlap regions, such as by fusion.

Details of exemplary overlapping panel configurations and non-overlapping panel configurations, as well as fusion of these panels, will now be described with particular reference to fig. 1A-5C. These figures may be used to show cross-sectional views or partial cross-sectional views of a headgear according to the present disclosure or of various components that may be used to construct the headgear.

Fig. 1A is a cross-sectional view of two overlapping panels (a first panel 1 and a second panel 2).

The panel may be selected from any suitable panel-like material. Suitable materials may include textiles as natural and/or artificial fiber networks, and more particularly may be fabrics made by braiding, knitting, spreading, crocheting, bonding, or other available methods.

The panel may also comprise any other non-conventional textile material, such as plastics or composite materials, which may be provided in panel-like form.

According to at least some configurations, each panel may be a single sheet or layer of one material or a unitary composite of materials, as opposed to multiple layers of the same or different materials.

The panels may be sheet-like in form or may comprise tubular panels.

The panel may have a 2D shape. Alternatively, one or more panels forming the headgear may have a 3D shape.

In at least some embodiments, some or all of the plurality of panels may be flexible materials, particularly materials that may hang down under their own weight. Such materials may be particularly suitable for forming headgear components that conform to the shape of the patient's head.

Each of the plurality of panels comprising the headgear defines two opposing major faces. In at least some embodiments, the major faces can overlap and join each other in the one or more overlapping regions of the headgear.

The plurality of panels may each be panels of the same material.

In various forms, at least some of the panels may be of different materials.

Different panels, which may include different materials, for example, may define various material properties or characteristics. The headgear formed from these panels may in turn be defined by these material properties. In the case of handling panels by fusing or fusing overlapping panels together, the characteristics of the respective panels and headgear may be further altered by fusing.

The material properties of the panel include its stretch properties. The stretch properties of the panel, or the headgear, or a portion of the headgear, refer first to its in-plane extensibility. A panel with relatively greater extensibility has relatively greater extensibility and vice versa.

In-plane stiffness of a panel refers to the degree to which the panel resists in-plane expansion or stretching. In contrast, the flexibility of a panel refers to the out-of-plane stiffness characteristics of the panel, such as the extent to which the panel will sag.

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

The stretchable panel may be a panel having at least some in-plane extensibility. The non-extensible panel may be relatively inextensible in-plane in at least one direction.

The panels may have stretch characteristics that are different from one another. For example, a first panel may have a first extensibility and a second panel has a second, different extensibility.

Where the panels overlap each other but are not fused together, they may define another third extensibility. Where the panels overlap and fuse, they may define another fourth extensibility. Still further, the first panel or the second panel may not overlap but instead be fused, a fifth extensibility may be defined that is different from the respective one of the first extensibility or the second extensibility.

A panel having stretch characteristics such that the extensible panel may or may not allow some or all of the stretch to recover when the stretch load is removed. In at least some configurations, the stretch characteristics of the stretchable panel may include recoverability such that the panel may be stretched and then, when the stretch load is removed, the panel may return to or toward its original unstretched shape.

Restorability may be achieved, for example, by elasticizing the panel. The elasticized panel comprises at least one elastomer, rubber, or rubberized component. For example, the elasticized panel may comprise at least some fibers of such elastic materials. In contrast, a nonelastomeric panel is a panel that does not include any such elastomeric, rubber, or rubberized components. The elasticized panel has a greater elasticity due to the at least one elasticizing component than an inelastic panel of the same material but without the at least one elasticizing component.

The characteristics of the panel may include the texture of the panel at one or both of its major faces, or at one or more edges bounding both major faces.

Another characteristic of the panel may be the softness or stiffness of one or both of the major faces, or one or more edges defining the two major faces of the panel.

Other characteristics that one or more of the panels may have include different densities, surface hardness, young's modulus, thickness, color at one or both major faces or defined edges, coefficient of friction at one or both major faces relative to a reference material. The different material properties may also include different degrees of breathability, different degrees of hydrophobicity or hygroscopicity, different permeabilities, or different transparencies or transparencies.

In addition to having any such different material properties between the panels, each panel itself may have one or more such properties that differ in direction or position within the panel itself. For example, as previously described, the panels may have directionally different stretch characteristics. The panel may also have directionally different textures or softness, flexibility or coefficient of friction.

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

Another example of a feature of a textile panel may be that it includes a cut pile or an uncut pile. Whether the pile is cut or uncut may provide different surface features. For example, an uncut pile may present a loop of material at the panel surface. Such materials with uncut pile surfaces may be commonly referred to as complete loop (UBL) materials.

The presence of such loops may be desirable for use as loop portions of a hook and loop fastener system. With this configuration, a hook and loop fastener system can be provided without having to attach any additional loop providing components to the panel. This may help, at least to some extent, to provide a headgear of reduced thickness.

One or more panels to be used in the headgear may be fanned out, meaning that their constituent fibers may be fanned out.

Additionally or alternatively, one or more panels to be used in the headgear may not be able to unravel, which may be referred to as free-cutting material. Such material may be cut and may not or may be at least resistant to the spreading of the constituent fibers along the cut edge. Advantageously, such materials can be cut into specific shapes, wherein the cut edge of the panel forms the edge of the headgear without further processing.

A panel having the following materials may be selected: these materials have any other material characteristics or panel configuration, such as may provide the desired function of a headgear that will include a panel.

In addition to the different material properties and characteristics provided by the combination of different individual panels, composite characteristics may also be provided at the overlap regions where the panels overlap.

For example, the respective panel thickness will form a lap zone having a thickness equal to the sum of the respective panels.

In another example, one panel may extend in one direction at the overlap region, while another panel may extend in another direction at the overlap region that is different or possibly perpendicular to the direction of the previous panel. In particular, in the case where the panels are only extensible in directions perpendicular or substantially perpendicular to each other, such a function may be provided: the panels may stretch in their respective directions at the non-overlap regions, but may be substantially inextensible at the overlap regions.

It should be appreciated that many other such combinations of panels having one or more different material properties may be configured to have desired properties at both the non-overlap region and the overlap region.

In addition to using panels having one or more different material properties, the properties of the headgear may be determined at least in part by the different configurations of the respective overlapping panels of the headgear at the one or more overlapping regions.

The overlapping regions of the headgear may be joined together entirely or only partially. For example, the overlap region may include both a joined region where adjacent panel surfaces have been joined together and a non-joined region where adjacent panel surfaces have not been joined together.

The panels that are joined together may be joined directly to one another. A direct bond between two panels is a bond of two panels to each other without any other material between the two panels. For example, a direct bond between two panels would exclude any intervening adhesive or intervening intermediate layers. A direct bond may be a bond of one or both materials of the respective panels to each other.

According to various embodiments, at least a portion of the overlapping region of the headgear may have its panels joined by fusion.

Fig. 1B shows the first panel 1 and the second panel 2 of fig. 1A having been joined together by fusion.

Fusion defines the melting of the panel or at least the constituent materials of the panel. With respect to fusing two panels together, fusing refers to fusing one panel into the other panel or fusing two panels to each other, respectively. Thus, the two panels may be fused by either: a) Only one panel or mainly one panel into the other panel, or b) both panels are melted into each other at the same time.

Accordingly, the panels to be fused should comprise a meltable material, such as rayon. Such as a polymer. Similarly, when the two panels are fused together, at least one of the two panels should comprise a meltable material, such as rayon.

As shown in fig. 1B, the overlap areas 21 of the first and second panels 1, 2 of fig. 1A have been fused to each other, or one has been fused into the other at their overlap surfaces, such that they are integral with each other and define a fused panel 6.

In one form, the fusing of one or more panels may be non-additive in that the fusing involves a process applied to the one or more panels and does not involve the use of any additional material, such as an adhesive interposed between the two panels to fuse them together.

Fusion may involve the application of one or both of heat and pressure to one or more panels.

Fusion may generally be performed by welding.

When the panels are fused together by welding, one or more of the panels are of a weldable material.

The weld may comprise the form of a plastic weld.

For example, the fusion may be provided by Radio Frequency (RF) or High Frequency (HF) welding, wherein the material to be fused comprises a dipole material that is heated and melted by electromagnetic excitation. Examples of materials that can be fused by radio frequency or high frequency welding include PVC, CPVC, polyurethane, EVA, PVDC, PET, and nylon. Fusion of radio frequency or high frequency welding may be provided to a material comprising at least partially a dipole material.

Other examples of materials that can be fused by radio frequency or high frequency welding include PETG, TPU, and LDPE.

Thus, one or more panels to be fused by welding (including by radio frequency or high frequency welding) may comprise or consist of dipole materials, which may be welded by these processes. When a fusion process (such as welding by radio frequency or high frequency welding) is applied to one or more panels, the one or more panels may typically be caused to solidify or set, respectively.

One or more panels may be fused to varying degrees. For example, in the case of radio frequency or high frequency welding, one or more of the welding platen spacing, welding energy, and welding time may be varied to increase or decrease the degree of fusion.

A relatively low degree of fusion may cause partial or localized consolidation of the fused material. A relatively greater degree of fusion may result in more complete or complete consolidation of the fused material. Exposure to a sufficient degree of fused material can cause the original material (e.g., a dipole fabric) to form a solid plastic where it fuses.

When the panels are to be fused by high frequency welding, the panels specifically comprise nylon, and in particular nylon content of about or greater than 80%. The remainder of the panel may comprise spandex or other similar polyether-polyurea copolymers.

Especially when the panel is a fabric fused by high frequency welding, the fabric may have a weight of about 160g/m ² Or greater density.

Other examples of suitable welding methods for fusing one or more panels include ultrasonic welding, vibration or friction welding, hot wedge welding, hot air welding, and induction welding.

The fusion of the two panels is at least predominantly the fusion of the faying surfaces of the respective panels.

The panels that are joined together by fusion may have varying degrees of how they are fused together. Such degree of fusion may be defined by the peel force between the fused surfaces; given some reference peel angle, the force required to peel the two fused surfaces apart.

The panels that are joined together by fusion may define a fusion zone where the peel force required to peel the panels apart is not zero. In particular, the peel force at the fusion zone may be significant and may even be such that the panels cannot be peeled apart without damaging the respective panels.

The panels joined by fusion may further define an unfused region where the peel force separating the panels is zero or substantially zero.

In addition to the fused and unfused regions, the panels joined by fusion may define one or more transition regions where the peel force transitions between the peel forces of the fused and unfused regions. The transition zone may define a peel force gradient between the peel force of the fused and unfused zones.

The transition zone may be defined by a peel force across its entire area between the peel forces of an adjacent fused zone and an adjacent unfused zone. The transition zone may additionally or alternatively be defined by a reduced density of the fused region relative to the adjacent fused region, and thus the average peel force required to separate the two panels is relatively small compared to at the adjacent fused region.

One or more of the landing zones may be fully fused so that all or substantially all of the landing surfaces are joined together. For example, the entire landing surface may be joined together, except for some smaller portions, such as might be used, for example, to provide a desired texture or surface finish to the headgear. Substantially the entire overlap surface may be about 90% overlap area, or even about 95% overlap area.

Additionally or alternatively, one or more overlap regions may be partially fused, defining fused and unfused regions within the overlap regions.

In addition to or instead of being characterized as being fully or substantially fully fused, the fused configuration of the panels of the headgear according to the present disclosure may be described by a straight line condition. Depending on the line condition, a line is drawn between any two edges of the overlapping region of the headgear or a portion of the headgear (such as the rear portion). Along a defined line, the length in the fused region is greater than the length in the unfused region. In other words, along the straight line, the welded length is greater than the non-welded length.

The weld length of the wire satisfying the straight line condition may be any length between most of the total length of the wire and the entire length of the wire.

The straight line condition may be satisfied between two given points, such as between the upper edge of the overlap region of the rear portion of the headgear and the lower edge of the overlap region.

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

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

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

Along a line that satisfies the straight line condition, the fused length and the unfused length may be arranged in a specific manner. For example, the overlapping panels may be fused at the ends of the lines adjacent to each respective edge. In this configuration, any unfused portions along the wire are disposed along one or more central portions of the wire, distal to the wire ends.

In some configurations along a line that satisfies the straight line condition, the unfused portion along the line is located only distal to the line end.

When the line between the two edges of the overlap meets the straight line test and the fused portion is located at both ends of the line, the cumulative length of the end portions where the overlap is fused along the line may be greater than the cumulative length of any central unfused portion along the line.

While generally described with respect to the rear portion of the headgear, other portions of the headgear (such as one or more straps of the headgear) may also satisfy the straight line condition at one or more locations along its length or along its entire length.

Fusion of a panel or panels may alter one or more characteristics of the panel or panels.

For example, melting and resolidification of the panel material may cause one or more of the following to occur in the panel: becomes thinner, denser, stiffer, less stretchable, less recoverable, or has a greater yield strength when stretched. Accordingly, selectively fusing headgear at different overlap and non-overlap regions may allow for control of headgear performance in addition to joining panels together.

For example, fusing of particular portions of the headgear may be utilized to create a load transfer path between different portions of the headgear.

Conversely, the unfused portion of the headgear may be positioned to define an extension region or an area of relatively greater thickness or flexibility.

Fusion of one or more panels may also alter one or more surface characteristics of the panels. For example, when the panel has a complete ring material at the surface, melting and resolidification of the panel or its constituent materials may reduce the number of complete rings present at the surface of the panel. This may reduce the effectiveness of the hook coupling of the panel to the hook and loop fastener. It may even serve to prevent hooks of a hook and loop fastener system from being able to couple with a panel.

Accordingly, selective fusion and non-fusion of portions of the panels may provide portions of the same one or more panels having a full annular surface and other portions not having a full annular surface.

In addition to providing the desired performance of the headgear, the selective fusion-of the fused portions of one or more panels, the degree to which these fused portions are fused, and the shape or orientation of the fused portions of the panels-may be used to provide different characteristics to the panels to alter the "feel" or appearance of the headgear. This may be used to provide cues to the patient or other user regarding the orientation or use of the headgear.

Fig. 2A shows a first panel 1 and a second panel 2 overlapping each other to define an overlap region 21, which have been partially fused together.

Most of the overlap region 21 has been fused to define the fused region 41, while the remainder of the overlap region is unfused and defines the unfused region 51. At the non-fused region 51, the panel 1 and the panel 2 are not joined to each other by fusion, and at this region, the peeling force required to separate the layers is zero or substantially zero.

Fig. 2B shows the panel lay-up (lay-up) of fig. 2A, but wherein the lay-up has a second non-fused region 52 dividing the fused region 41 of fig. 2A into a first fused region 41 and a second fused region 42.

These panels may or may not be fused at different regions of any configuration to provide the desired features of the headgear.

Fusion of the panels, such as one or both of the panels being fused or partially fused into each other by welding, may result in thinning of the panel lay-up at the fusion zone. This may be especially the case in the following cases: fusion is provided by applying pressure at the panel portions to be fused.

Fig. 3A shows a lay-up of a first panel 1 and a second panel 2 that have been partially fused to define a non-fused region 51 and a fused region 41. At the fused area, the thickness of the lay-up is less than at the unfused area of the panel.

Fig. 3B shows the same lay-up as in fig. 3A, but with two spaced apart fused regions 41 and 42 and two unfused regions 51 and 52. The first non-fused region 51 is at the end of the panel. The second non-fused region 52 is located between the two fused regions 41 and 42.

Fig. 1 to 3 show a configuration in which two panels are completely overlapped with each other. The panels may also be arranged in other configurations, such as where one or both of the panels define a non-overlapping region, or where the panels are in edge-to-edge abutment with one another. Fig. 4A shows a lay-up with a first panel 1, a second panel 2 and a third panel 3 exhibiting some such configurations.

In fig. 4A, the first panel 1 and the second panel 2 are each partially overlapped with each other. Then, the third panel 3 partially overlaps the second panel 2, and the edges of the first panel 1 and the third panel 3 abut each other.

The arrangement of fig. 4A defines a first non-overlap region 31, an overlap region 21 and a second non-overlap region 32.

Fig. 4B shows the arrangement of fig. 4A, wherein the panels are fused together. As shown in fig. 4B, the overlapping surfaces of the first and second panels 1 and 2 and the second and third panels 2 and 3 have been fused together.

As also shown in fig. 4B, the abutting ends of the first panel 1 and the third panel 3 have been fused together.

The characteristics of the headgear at the overlap or non-overlap regions are also affected by whether and to what extent one or more panels are fused.

For example, fusion of the panel by its fusion may result in one or more of the following: localized thinning, reduced ductility, or reduced flexibility at and possibly adjacent to the fusion zone.

Accordingly, the fused regions of the headgear may be located at both the non-overlap region and the overlap region to provide the headgear with desired characteristics.

One or more of the panels may also be fused at the non-overlapping regions of the headgear. Fusion at the non-overlap region may act to alter the material properties of the panels rather than to join the two panels together.

Fig. 5A shows a first panel 1 and a second panel 2 partially overlapping each other to define a first non-overlapping region 31 of the first panel, an overlapping region 21, and a second non-overlapping region 32 of the second panel.

Fig. 5B shows the result of fusion applied to the overlap region 21 and a portion of both the first non-overlap region 31 and the second non-overlap region 32. In the illustration of fig. 5B, the fusion is such that it results in thinning of the panel or panels to which the fusion is applied.

As shown in fig. 5B, the fusion results in a panel having a first fused region 41 of the first panel, a second fused region 42 of the fused overlapping first and second panels 1, 2, and a third fused region 43 of the fused second panel 2. The remaining lateral portions of the first and second panels, respectively, are not fused and define first and second unfused regions 51, 52.

The panels may be singly overlapped, as shown in any of fig. 1A-4B, wherein the panels overlap or overlap only one other panel. When the single lap panels are joined together, they form a single lap joint. The panels may also be double-lapped such that one panel overlaps and overlaps two other panels on both respective major faces of the panel. The case where double lap panels are joined together may be referred to as a double lap joint.

Fig. 6A shows a lay-up in which the first panel overlaps and overlaps, or double overlaps, the second panel 2 and the third panel 3, respectively. The lay-up defines a first non-overlap region 31, an overlap region 21 of the first panel overlapping the second and third panels on each side, and second and third non-overlap regions 32 and 33 of the second and third panels 2 and 3, respectively.

Fig. 6B shows a first fusing arrangement of the lay-up of fig. 6A, wherein the overlap region 21 is fused. The fusion of the overlap region 21 joins together the two overlapping surfaces of the first panel 1 and the second panel 2 and the first panel 1 and the third panel 3, respectively.

As shown in fig. 6B, each of the non-overlapping regions 31-33 remains unfused. At the non-overlap regions 32 and 33, the second and third panels are shown overlapping each other due to fusion of adjacent overlap regions.

Fig. 6C shows another fusion arrangement of the lay-up of fig. 6A, wherein fusion has been applied over the entire section to define a first fusion zone 41 of the first panel, a second fusion zone 42 of the overlap region 21, and a third fusion zone 43 of the second and third panels, which have now been fused together.

A double lap joint such as that shown in fig. 6B or 6C may have the following advantages over a single lap joint: the likelihood of inducing torsion in the joint under side loading of the respective panel is reduced. Such twisting may cause the connector to twist or otherwise deform such that at least a portion of the headgear cannot lie flat. This may be undesirable in some situations, for example where the headgear is laid flat on the patient's head, as any such twisting of the headgear may result in a point of increased pressure on the patient's head, resulting in discomfort.

Reducing or eliminating torsion at the interface between the panels may also increase the strength of the headgear where the panels are joined or bonded together. Torsion of the panels at the joints may cause them to be subjected to peel stress when the panels are under tension. The joint may have a relatively limited strength under such peel stress, wherein the panels are pulled away from each other perpendicular to the joined surfaces. The reduction in torsion may mean that the panel is not twisted and exposed to peel stress, but is primarily or solely exposed to shear stress. Some bonds, particularly fusion or welded bonds, may be capable of providing greater strength under shear stress than under peel stress. This means that the strength of the headgear can be increased by reducing torsion at the overlapping panels.

In other configurations, a single lap joint may be preferred over a double lap joint, for example, where the load does not cause significant torsion in the joint, as it may provide a thinner joint.

The single lap joint of the arrangement of fig. 4A and 4B may also act similarly to a double lap joint in terms of reducing torsion and thus potentially increasing the strength of the joint, where side loads will be applied to the first panel 1 and the third panel 3.

While various example overlays of different panels have been described above, as well as different fused and unfused configurations of such panels, it should be appreciated that any number or combination of such overlays and fused configurations thereof may be provided to form a headgear.

While shown as including various panels having a representative thickness, it should be appreciated that the above-described lay-up may be provided with panels having different thicknesses and combinations of thicknesses, as well as any other desired material characteristics.

Unless the context indicates otherwise, the perimeter of a panel, portion, area, or headgear itself may generally be understood to refer to the perimeter of the respective panel, portion, area, or headgear, and more specifically to the boundary within the perimeter. This may also be otherwise referred to as an inner perimeter when context requires.

Conversely, the outer perimeter of a panel, portion, area, or headgear itself will generally be understood to refer to the boundary outside the perimeter of the respective panel, portion, area, or headgear.

Fig. 7A to 7C show plan views of two panels to form part of a headgear.

As shown in fig. 7A, the first panel 1 is disposed below the second panel 2, which completely overlaps the first panel. These panels define a lap zone 21 of the same size as the second panel 2. The panels will be joined together to form part of the headgear. They may be joined by fusion or in particular by welding, as already described. They may additionally or alternatively be at least partially joined by any number of methods, such as stitching or by using an adhesive. For the purposes of this example, the panels will be joined by fusing together, particularly by welding.

Fig. 7B shows a shaded dividing line representing a weld 70 around the perimeter of the overlap region (i.e., where the panel 1 and panel 2 of fig. 7A are joined).

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

However, due to the narrow nature of the weld and the fine tolerances necessary to weld the panels around the perimeter of the overlap region 70, difficulties may arise. If one or both of the panels are not placed in their correct position relative to the welding tool, or if the tool is misaligned relative to the panels, the weld may not eventually be in its desired position.

Fig. 7C shows the arrangement of fig. 7B, but with the weld 70 misplaced relative to the panels 1 and 2. As a result, the weld 70 is located partly outside the limits of the second panel 2 (at the left and top of the second panel) and partly only within the limits of the second panel (at the bottom and right of the second panel). This may mean that the panels are not properly joined together.

Although shown in fig. 7C as misalignment between the panel and the bonding tool, it should be understood that the misalignment may additionally or alternatively be introduced due to the position of the panels relative to each other. Furthermore, while the misalignment in fig. 7C is shown as a translational misalignment, it should be understood that there may additionally or alternatively be a rotational misalignment.

If the width of the weld 70 increases, problems associated with misalignment may be minimized such that the intended degree of misalignment will not result in the joint being located outside the perimeter of the second panel 2. These problems can also be minimized if the weld 70 is arranged to extend past the overlap area of the panels to a position where only the first panel 1 is properly aligned. However, such changes may be contrary to conventional teachings in that they involve increasing, rather than minimizing, the area of the panel where welding occurs.

Even if the width of the weld increases and the weld is positioned to extend beyond the overlap area, misalignment may reduce the total amount of connected area of the panels, thereby reducing the strength of the joints thereof.

Fig. 8A-8C illustrate additional methods of avoiding joint misalignment. Fig. 8A shows the same arrangement as fig. 7A, wherein the first panel 1 completely overlaps the second panel 2.

Fig. 8B shows the same panel, wherein the weld 70 is applied over the entire overlap region 21 and also extends beyond the overlap region to the non-overlap region of the first panel 1.

Fig. 8C shows the arrangement of fig. 8B, but with the welds and panels misaligned with one another. Because the weld 70 is larger than the second panel 2, misalignment can be compensated and the entire overlap area 21 is still welded. In addition, because the weld 70 covers the entire area of the second panel 2, rather than just the parting line around its inner and outer perimeter, the effect of any misalignment on the total weld area of the overlap area can be reduced.

Accordingly, it may be desirable to increase or even maximize the welding area of the headgear.

Fig. 9A and 9B illustrate a welding apparatus 500, such as a high frequency welder, for welding a face plate of a headgear.

The welding apparatus 500 includes a top welding platen 501 and a bottom welding platen 502. The platen has an upper die 503 and a lower die 504. The platens may be moved away from each other to open the mold and may be moved together to bring the mold closer for welding.

The panels, such as the first panel 1 and the second panel 2, are located between the two molds.

The upper and lower dies each define a die face 506. The faces are adjacent to each other across the panel to provide fusion of the panel.

Depending on the type of welding used, the die faces will interact differently to provide fusion of the panel material therebetween. For example, in the case of direct thermal welding, one or both of the dies may be heated to melt the panel pressed between the dies. Alternatively, in the case of ultrasonic welding, vibration of the mold at the mold face contacting the panels will heat the panels and provide fusion of the panels.

In the example of high frequency welding, the electromagnetic field provided across the mold has sufficient strength between the two mold faces 506 to excite and melt the dipole material located between the mold faces.

While one or both of the dies may be heated for direct thermal welding, one or both of the dies may also be heated where other types of welding are used, such as ultrasonic welding or high frequency welding.

When one or both of the molds are heated, they may be heated, for example, to about 100 ℃.

Such heating of one or both of the dies may raise the temperature of the panel prior to fusion of the panel. This may increase the effectiveness of the fusing operation.

One or both of the upper mold 503 and the lower mold 504 may include one or more recesses of the mold facing away from the mold face 506. As shown in fig. 9A and 9B, the upper mold 503 includes a recessed area 505. The recess creates a relatively increased distance between the two molds at the recessed area 505. This increased distance may reduce the degree of welding of the material within the coverage of recessed area 505. It may even leave the material in the coverage of the recessed area unwelded or at least substantially unwelded.

For example, in the case of direct thermal welding, the upper mold 503 will not contact the panel at the recessed area 505 and, correspondingly, will not melt the panel at the recessed area. Similar functions apply to the case of ultrasonic welding.

In the case where the panels are to be fused by high frequency welding, the recess 505 will create a region of reduced electromagnetic field strength and thus reduce heating of the panel at the recess 505. The recess 505 may have a depth sufficient to prevent melting of one or more materials of the panel at the recess 505.

Thus, the power supplied to the high-frequency welding apparatus and the spacing between the portions of the two dies can be used to control where the panels are to be fused and to what extent they are to be fused.

The regions of the dies that are closest to each other during welding may cause the panel portions therebetween to fuse, while the panel portions between the less proximate portions of the two dies may fuse or remain unfused to a lesser extent.

Accordingly, the design of one or both of the molds that will design the shape of the mold face 506 and the location and depth of any recessed areas 505 may allow for control of which portions of the headgear are fused and to what extent they are fused and which portions of the headgear remain unfused.

The faceplate of the headgear will be placed between the upper die 503 and the lower die 504 in the welding apparatus 500. One or more of the panels may include an alignment feature 8, as will be described in connection with fig. 28A and 28B. The alignment features may interface with corresponding features of one or both of the molds to hold one or more panels in their desired positions relative to the molds.

Once the panels are in their desired positions, the upper die 503 and lower die 504 may be brought together and welding of the panels initiated.

Fig. 9B shows a welding apparatus 500 in which platens 501 and 502 and dies 503 and 504 have been brought together to weld panel 1 and panel 2.

The mold may be brought into a predetermined proximity of one or more panels. In some configurations, the mold may apply pressure to the one or more panels, or at least to the areas of the panels to be welded together.

The fusing of the panels may be provided in a 2D manner as shown in fig. 9A and 9B, wherein the panels lie flat or substantially flat between the two molds.

The panels or panel portions may be welded in a 3D shape. For example, the mold may have a complementary 3D shape such that the panel hangs down on the mold in a desired manner. Then, when the panel hangs down in its 3D shape, welding may be applied to the panel. This may be advantageous in forming headgear having a 3D shape.

Although not shown in fig. 9A and 9B, one or more layers of non-stick material, such asTo prevent sticking of the panel to the mould or moulds.

Although described using examples of high frequency welding, it should be understood that the panels may be fused together as described by any number of other fusion methods and in particular by plastic welding, including ultrasonic welding, vibration or friction welding, hot wedge welding, hot air welding, or induction welding.

Fig. 10 illustrates a patient 700 wearing headgear 10 to secure patient interface 600 to the patient's face. The headgear 10 has an outer surface 4 which faces away from the patient in use, and an inner surface 5 (not visible in figure 10) which faces towards and contacts the patient in use.

The outer and inner surfaces of the headgear may be the same or different from each other. The inner and outer surfaces of the headgear may be defined by panels having the same characteristics or different characteristics. For example, the colors or textures of the surfaces may be different from each other to help inform the patient of the orientation of the headgear.

As shown in fig. 10, the headgear 10 has a rear portion 100 located at the rear of the patient's head. Two side ties are shown, an upper tie 301 and a lower tie 302. The side straps connect the headgear to the patient interface 600. As shown in fig. 10, the headgear also has a crown strap or top strap 200 that passes over the patient's head.

Corresponding two side straps, an upper strap 303 and a lower strap 304, may be connected to the hidden side of the patient interface 600.

Where there are multiple sets of side ties on each side, the area between the two side ties may define an ear loop 320 as shown in fig. 11. Ear loop 320 includes a portion of the headgear that extends between each respective upper and lower strap on one side of the headgear. Each upper strap 301, 303 passes over an ear and each lower strap 302, 304 passes under an ear. Ear loops 320 are positioned at least behind the ears. The edge of the ear loop between each upper and lower strap may be curved or may include a plurality of linear edges arranged about a nominal curve.

It will be appreciated that given a range of different patient head sizes, the harness may be provided in a length shorter or longer than that shown in figures 10 and 11 sufficient to reach and couple with the interface.

In other embodiments, the headgear 10 may include only two side straps, one for connection to each side of the interface.

Fig. 11 shows a flat-laid view of an embodiment of the headgear 10.

Headgear 10 has a central region 15 and two lateral sides 16 and 17. The central region 15 is intended to be positioned on the rear middle of the patient's head, while the two lateral sides 16 and 17 extend around the patient's head for use towards the respective sides of the patient interface.

As shown, the lateral sides 16 and 17 are shaped to pass around the patient's ears.

The height of the headgear taken in a direction perpendicular to the lateral direction around the patient's head, and shown by line 807 in fig. 11, is greater at the middle of the central region 15 than at the portion of each lateral extension 16 and 17. In particular, as shown in fig. 11, the lateral extensions 16 and 17 narrow to about 30% to 50% of the height of the headgear at the middle of the central region 15.

As shown in fig. 11, the height of the second panel 2 is substantially equal at the middle of the central region 15 and at the narrowing of the lateral extension, while the height of the first panel is greater at the central region 15 than at the narrowing of the lateral extension.

Headgear 10 has a rear portion 100 and a plurality of straps. Specifically, the headgear 10 has a pair of upper straps 301 and 303 and a pair of lower straps 302 and 304. The headgear also has a top strap 200.

In other forms, headgear 10 may include a rear portion and two side straps, one for connection to each side of the patient interface.

The strap may further comprise one or more panels identical to the rear portion.

The one or more tethers or at least a portion of the one or more tethers may be formed from one or more fused panels according to the present disclosure. Additionally or alternatively, the tie may be formed of another material (such as laminated foam). Where the straps are not formed from one or more fused panels, they may still be joined to the remainder of the headgear by fusing to one or more panels of the headgear.

Although the upper tethers 301 and 303 are each shown in fig. 11 as being formed from the same panel as the corresponding portion of the top tether 200, each tether may be a separate portion.

In other forms of headgear with two side straps on each side, the adjacent straps 301 and 302 and 303 and 304 may be formed from one or more of the same one or more panels as each other. In still other forms, each of the adjacent tethers 301 and 302, 303 and 304, and the adjacent portion of the top tether 200, may be formed from one or more of the same one or more panels as each other.

Although shown as including two strap portions, the top strap 200 may be a single strap attached back to the rear portion 100 of the headgear in some forms.

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

The harness strap may include features 330 to facilitate tightening the strap to the patient interface, or to itself in the case of the top strap 200. An example of such a feature 330 is shown in fig. 10. These features 330 may be, for example, one half of a hook and loop fastener, where the other half may be provided by a surface of the headgear (such as a portion of a strap or rear portion).

While the headgear may be illustrated without any straps or other features for attachment to the patient interface, it should be understood that the headgear, or particularly the rear portion 100 of the headgear, may include any suitable number or arrangement of straps or other securing devices as desired to facilitate connection thereof to and adjustment relative to the patient interface.

Fig. 12 shows a first panel 1 and a second panel 2 that may form part of a headgear 10 according to an embodiment. These panels each have a central region 15 and two lateral sides 16 and 17. The central region 15 of the second panel has a cut-out in its lower part.

As shown in fig. 12, the incision is located between the rear section of the band 110 and the two lower strap connecting portions 120a and 120b of the headgear.

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

Fig. 13 shows the panel 1 and the panel 2 of fig. 12 stacked on top of each other. The second panel 2 is located entirely within the first panel and the overlap region 21 defined by the panels is therefore of the same dimensions as the second panel.

The overlapping panels define a first non-overlapping region 31 around the outer periphery of the second panel (where there is a protruding border of the first panel 1) and a second non-overlapping region 32 at the centre of the rear portion 200 defined by the cut-out of the second panel 2.

The panels may be sized such that at one or both of the lateral extensions 16 and 17, the height of the second panel may be about 70% to about 80% of the height of the first panel at the same portion.

Since the headgear has only the thickness of the first panel 1 at the second non-overlap region 32, it may define a thinner or more extensible region than the remainder of the overlap region 21.

Since the posterior portion will be located at the posterior portion of the patient's head, the lower extent of the posterior portion will be located around the upper portion of the patient's neck. The upper portion is an area that may have a significantly variable geometry between people of different anatomy and thus may be a point of discomfort for a patient using a given headgear.

According to various forms where the first panel is made of a stretchable material, the non-overlap region 31 may function to allow stretching to accommodate the geometry of the patient's neck. Accordingly, the non-overlap region 31 at the cut of the second panel 2 may be characterized as the stretch zone 80.

The stretch at stretch zone 80 may be greater than the extent allowed by at least the adjacent portion of the headgear, and in particular greater than the overlap region 21 shown in fig. 13.

Although according to various embodiments, the first panel 1 may entirely overlap the second panel 2, according to other embodiments, the first panel 1 may overlap the second panel only around the boundary of the cutout of the second panel 2. With this configuration, the headgear may still provide the stretch function previously described, but the first panel may have a relatively small size.

The cutout of the second panel relative to the first panel may be substantially semi-circular or crescent-shaped to define the stretch zone 80, as shown in fig. 13.

The cutout may have a lateral dimension that increases toward the bottom of the headgear to allow a relatively larger expansion toward the bottom of the headgear to accommodate a larger lower neck dimension.

The first non-overlapping portion of the first panel 1 surrounding the second panel 2 may be a free edge, without seams. It may be edge-processed somewhat, or without any edge processing.

In various forms, any edge treatment of the panels may be provided by fusion of one or more panels.

The absence of seams and/or any edge treatments at the lower edge may increase the comfort of the headgear to the patient by providing continuous characteristics (such as stretch, stiffness and thickness) over the portion of the first panel 1 overlapping the second panel up to the full extent of the edge of the first panel.

Since the first panel 1 beyond the second panel 2 is unsupported and may be substantially non-load bearing, it may curl or curl away from the patient's head when in contact with the patient's head. This may create a region of reduced patient head pressure from the edge of the overlap region to the distal edge of the first panel 1.

Such a region of progressively lower pressure may have an edge softening effect and provide increased comfort to the patient as opposed to a sharp drop in pressure on the hard edge (which may make the patient more aware of the presence of headgear or cause pressure irritation to tissue at the edge).

The panels of the rear portion 100 may be fused together to join them and define a portion of the headgear.

Fig. 14 shows the rear portion 100 of fig. 13, wherein the panels have been fused together, such as by welding applied to the panels. As shown by the shading in fig. 14, the fusion zone 41 covers the entire overlap region 21, so that all the overlapping portions of the first panel 1 and the second panel 2 are fused together.

The first non-overlap region 31 of the boundary of the first panel is not fused and therefore may retain softer, more flexible, or more stretchable properties than the fused panel at the fused region 41.

With such a configuration, the headgear can maintain a desired level of comfort around its edges.

Although fig. 14 shows the fused region 41 extending across the entire overlap of the first and second panels, various embodiments of the headgear may use one or more non-fused regions.

Furthermore, while the headgear of fig. 14 shows the fused region 41 covering only overlapping panels, various embodiments may include fusion of all or part of the non-overlapping regions. This may be for example to obtain the benefit of misalignment tolerances for the panels or fusion, as described with respect to fig. 7A-8C.

Fig. 15 shows the lay-up panel of fig. 13, showing the parting line 70 of the area to be fused extending beyond the perimeter of the second panel 2.

Fig. 16 shows a close-up view of the upper part of the central area 15 at the top of the cut-out of the second panel. The fused dividing line 70 extends to the outer periphery of the second panel, which is a margin or border beyond the peripheral extent of the second panel 2.

In fig. 16, as indicated by the dividing line 70, fusion is applied to both the inside of the periphery of the second panel 2 and to the first panel 1 at the outer periphery of the second panel 2, which is the boundary between the periphery of the second panel 2 and the line of the dividing line 70. As shown in fig. 16, the fusion is applied not only to the periphery of the second panel 2 but also to the entire area of the second panel.

Although shown in fig. 16 as being located at the outer perimeter of the second panel 2, the line of demarcation 70 may be located anywhere between the outer perimeter of the second panel and within the perimeter of the second panel. For example, the dividing line 70 may be located at the perimeter of the second panel 2. When the dividing line 70 is located within the perimeter of the second panel 2, the boundary around the perimeter of the second panel will remain unfused.

The distance that the dividing line 70 extends beyond the second panel 2 may be selected based on expected errors in placement of the panel relative to the fusion device during manufacture of the headgear.

The size of the dividing line may be continuous around the outer periphery of the second panel. In other configurations, the size of the dividing line may be variable around the outer perimeter of the second panel.

Although in some embodiments the dividing line 70 extending into the first panel 1 may cause the first panel to fuse, in other embodiments the first panel 1 may be melted to a lesser extent than the second panel or even not melted at all.

For example, the first panel may be made of a material having a higher melting point than the second panel. If the temperature of the material at which the fusion is provided does not exceed the melting point of the first material, the first material may not fuse when the fusion is applied to the first material.

In the case where the fusion is applied by high frequency welding, the first panel may contain less dipole material than the second panel, or may not contain any dipole material. Accordingly, the first panel is not heated and melted by the high frequency welding that may be applied thereto.

According to at least some embodiments, the entire perimeter of one or even all of the overlapping regions of the headgear may be fused together. The edges of the overlap area where the overlap panels are not joined together can be unsightly. The unattached edge of the overlap region may also introduce the possibility of the overlap panels undesirably peeling off at the adjacent portions where they fuse together.

Accordingly, in some embodiments of the headgear, the entire perimeter of each overlap region may be fused.

The rear portion 100 of the headgear may in some forms be configured to be directly connected to the patient interface and may thus define the headgear. For example, the lateral ends of the rear portion 100 may be equipped with a securing device for attachment to a patient interface, or may be otherwise adapted to couple with a patient interface, such as by adhesive on one or both of the rear portion and the interface.

The rear portion 100 may have a shape as shown in fig. 13, for example. The rear portion 100 may also have a different shape, such as may include one or more tethers formed by one or more of the panels that make up the rear portion 100.

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

Where the panels of the rear portion 100 are fused together, it may be desirable to also join the strap to the rear portion by fusion. This may be done in discrete steps, where the lace is fused to the already fused back portion. It can also be performed in a single step, wherein the panel and the tie (whether panels or other materials, such as foam fabric-foam laminate) of the rear portion are fused together in one operation.

Fig. 17A shows another embodiment of the rear portion 100 of the headgear 10, wherein the overlap region includes a fused region 41 and a plurality of unfused regions 51-54.

According to some embodiments, the non-fused region may be generally located at a portion of the headgear having a relatively increased height. In this way, an unfused region may be provided while still maintaining a certain amount of fused area across the lateral dimension of the headgear. Fig. 17A illustrates an example of such a case, in which a continuous fused zone is provided along at least a significant portion of the lengthwise direction of the headgear.

The headgear may define a zone 110 and a plurality of strap connection portions 120. An example of a headgear having a band 110 is shown in fig. 17A. The band 110 is a headgear portion that extends around the patient's head and transfers loads between at least two connection points to the patient interface. The strap attachment portions 120a-d depend from the zones and the strap is defined in whole or in part by or attached to one or more of the same panels, such as by fusing together.

It will be appreciated that the shape of the first panel 1 and/or the second panel 2 may be adjusted from the shape shown in, for example, any of figures 13 to 17, with the strap being defined in part or in whole by one or more of the headgear panels at the strap connection portion 120.

As shown in FIG. 17A, the headgear is primarily fused region 41 at zone 110, with the strap connection portions being unfused regions 51-54.

With this configuration, the headgear may have a region of relatively reduced extensibility that may transfer loads between sides of the headgear and a region of relatively greater extensibility at the strap connection portion. This may allow the extensibility to accommodate different tensions on the patient's physiology or tie.

Fig. 17B shows the rear portion 100 of fig. 17A, where it has been attached to a plurality of tethers 301-304 and 200.

As shown in fig. 17B, the ties are each sandwiched between the first and second panels at each tie connecting portion 120, and the first panel, the corresponding tie, and the second panel are all fused together at their overlapping portions.

As shown in fig. 17B, the fusion of the headgear at the strap connection portion 120 will cause each of the first panel 1 and the second panel 2 to be fused to a respective side of each respective strap.

Sandwiching the tie between the first layer 1 and the second layer 2 may provide the benefits of the double lap joint described earlier and thus provide the ability to reduce torsion at the joint under the load of the tie.

Headgear 10 as shown in fig. 17B may be first formed as the rear portion 100 of fig. 17A and then the straps attached as a separate step. In other forms, one or more of the tethers may be joined to the respective panels in the same step of fusing a portion or all of the panels to form the rear portion 100 of fig. 17A.

As shown in fig. 17B, when the laces are fused to the rear portion, they make there a continuous perimeter of the second panel 2 that is fused. This may prevent loose edges of the second panel, such as may allow the first and second panels to be peeled apart.

It should be understood that any of the embodiments described herein having a rear portion 100 of the non-fused region of the lap panel at the lacing connection portion may be fully or partially fused therein when the lacing is joined.

Fig. 18 shows another embodiment of the rear portion 100 in which the non-fused regions 51-54 are all enclosed within the uninterrupted fused region 41 of overlapping panels 1 and 2.

One or more of the fused regions may be discrete, or two or more of the fused regions may define an uninterrupted fused region, as shown in fig. 18.

The enclosing fused portion of the panel can influence how load is transferred through the headgear because load can be transferred from the strap to the fused strap connection portion and then through the fused portion of the headgear strap.

This may result in the rear portion of the headgear having relatively less overall extensibility than the embodiment of fig. 17A and 17B.

The unfused regions within the fused region 41 of fig. 18 may have a relatively greater extensibility than the fused region 41. Placing the non-fused regions 51-54 at the widest portions of the overlap region may reduce the overall resistance of the overlap region to stretching at these portions.

The non-overlapping portion of the first panel 1 may be the same or substantially the same size as the remainder of the non-overlapping portion of the first panel except at the stretch zone 80. Alternatively, the size of the non-overlapping portions of the first panel other than the stretch zone 80 may vary. For example, the amount of non-overlap of the first panel 1 at the ear loop 320 may be greater than or less than the amount of non-overlap of the first panel 1 around the top of the headgear strap portion 110 at the opposite side of the headgear.

The size of the non-overlapping portion of the first panel 1 surrounding the second panel 2 may be referred to as the boundary of the first panel. As shown in the configuration of fig. 18, the boundary formed by the non-overlapping portion of the first panel 1 around the ear loop 320 and along the upper edge of the back portion 100 has a substantially continuous width.

Although the border around the ear loops 320 and the upper edge of the back portion 100 in fig. 18 is of substantially the same size, in other configurations, the border may be of different widths in different areas. The width of the border of the custom non-overlapping panel allows for providing localized variation in the softness of the edge of the headgear when worn. When the first panel is an extensible material, controlling the width of the border of the non-overlapping panel at different regions may allow for controlling and restoring the deformation along the border, which may occur at the stretch zone 80.

For example, in some configurations, the first panel 1 may have a locally increased width of non-overlapping boundaries at the ear loop 320 or a portion thereof. This may act to prevent or limit the headgear from lifting off the patient's head when worn.

Fig. 18-1 and 18-2 are a flat-down view of another embodiment of the headgear 10 and a partial rear view of the headgear 10 when worn, respectively. As shown in fig. 18-1, the non-overlapping portions of the first panel 1 at each side of the ear loop adjacent to the stretch zone 80 have a locally increased width.

Between the respective lacing connection portions 120 and the zones 110, the non-overlapping portions of the first panel 1 have a larger radius of curvature such that the non-overlapping portions between the connection portions 120 and the zones 110 define a crescent shape.

When worn by a patient, such as shown in fig. 18-2, the force acting on the headgear 10 may, in at least some instances, cause the headgear to lift off the patient's head behind the patient's ears, at or toward the bottom of the curve between the strap connection portion 120 and the strap 110. If the headgear is subjected to these forces, the partially widened portion of the non-overlapping first panel may help limit or prevent the headgear from lifting off the patient's head between the strap connection portion 120 and the strap 110.

Fig. 18-3 illustrate four different configurations 100a-d of the rear portion 100 of the headgear 10. Each of the rear portions 100a-d has a first panel 1 partially overlapping a second panel 2, the non-overlapping portion of each first panel 1 forming a boundary of the respective portion around the periphery of the rear portion. In particular, the non-overlapping portions define a boundary at the back expansion region 80 and a boundary 83 at the ear loop 320.

Each of the back portions 100a-d exhibits a different configuration of the width of the non-overlapping border of the first panel 1 at the ear loop 320. Such different widths of the border may be provided by increasing the local size of the first panel 1 or by reducing the local width of the overlapping second panel 2 as in the configuration of fig. 18-3. In each next of the rear portions 100a-d, the second panel 2 has a relatively reduced width at the ear loop 320. In the case of the rear portion 100a, the boundary 83 is about half the width of the adjacent portion of the second panel 2. For the rear portion 100b, the width of the border 83 is about the same as the adjacent portion of the second panel 2. For the rear portion 100c, the border 83 is about twice the width of the adjacent portion of the second panel 2. Finally, for the rear portion 100d, the border 83 is approximately three times the width of the adjacent portion of the second panel 2.

Where the first panel 1 is an stretchable panel and the second panel 2 is a non-stretchable panel, reducing the width of the second panel 2 at the ear loop 320 may improve the ability of the headgear to conform to the shape of the patient's head in that region.

Fig. 19 shows another embodiment of a headgear. In fig. 19, substantially the entire overlapping portion of the headgear is fused to define a fused region 41. As previously described, it should be understood that the fused region 41 may extend beyond the second panel 2 and may encompass some or all of the non-overlapping area of the first panel 1.

The headgear of fig. 19 has non-fused regions 51-54 arranged as clusters of multiple small regions. As shown in fig. 19, each small region is circular; such a shape may minimize the tight geometry and correspondingly reduce the risk of arcing or burning of the panel around the parting line of each small non-fused and fused area.

In the event that fusion results in thinning or flattening of one or more fused panels, the configuration of fig. 19 will provide a headgear surface having clusters of bumps or bumps at each set of unfused regions 51-54.

This may provide the user with a tactile feature, such as helping the user orient himself to the headgear by the feel of the raised bumps.

Small clusters of adjacent non-fused regions can also be used together to create stretch zones where the headgear can have relatively increased extensibility.

By selecting different panel materials, the raised bumps at the non-fused regions can be more pronounced at one or the other of the inner and outer surfaces of the headgear. For example, relatively more pronounced bumps may be formed at the outer surface of the headgear than at the inner surface of the headgear, wherein the panel is compressed more at the outer surface than the panel by fusion.

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

A headgear of a given size may have a rear portion 100 of certain dimensions and proportions, as well as certain strap lengths.

To increase the ability of a given headgear size to accommodate different patient geometries, the straps may be lengthened. This may allow the headgear to fit patients with larger geometries. However, a harness long enough to accommodate a larger patient may present problems for users of the same size headgear with smaller geometries.

For example, where the tie end is secured by a securing device on the tie or a securing device of the tie (such as by a hook or loop portion of the tie end being connected to the other of the hook or loop portion of the tie), the tie end may return past the base of the tie for patients having smaller geometries. This may make a headgear of a given size unsuitable for patients with smaller geometries.

When the panel has a full ring material and the fusion process is such that it reduces the full ring density at the surface of the full ring material, one or more unfused regions may be utilized to maintain the area of the full ring. This may, for example, allow the strap securement device to be secured to the headgear at one or more non-fused regions.

For example, as shown in fig. 19, a cluster of small unfused portions of the headgear at each of the unfused regions 51-54 may provide a complete loop of sufficient density to allow a lace securing device having a hook portion of a hook-and-loop fastener to be secured to the headgear at one or each of the unfused regions 51-54.

The location of the one or more non-fused regions may be, for example, to provide a range of regions to which the lace securing device may be secured.

For example, as shown in fig. 17B, the first and fourth unfused regions 51 and 54 are each positioned along an extension line from a portion of their respective ligaments 301 and 200 and 303 and 200. Similarly, at least a portion of the second and third non-fused regions 52 and 53 are positioned at an extension from their respective ligaments 302 and 304.

While the non-fused regions may be located along an extension from the strap at the respective strap connection portion 120, or along an extension from any other distal portion of the strap, it should be appreciated that the non-fused regions may be located anywhere on the headgear that corresponds to where the user desires to be able to attach the strap securement device.

The rear portion 100 of fig. 18 illustrates a further example of non-fused portions 51-54 that may allow for attachment of a lace securing device. As shown in fig. 18, the intermediate non-fused regions 52 and 53 surround a significant portion of the overlap portion of the panel adjacent to the lacing connection portion.

As also shown in FIG. 18, the fused regions 51-54 are shaped to increase along a notional extension from where the lace is to be connected to its lace connection, such as shown in the lace of FIG. 17B.

The non-fused region to which the lace may be attached may be positioned directly adjacent to the base of the lace.

In the form of overlapping panels that are fused together having a continuous perimeter, the one or more non-fused regions may be located within the fused perimeter, but as close as possible to the base of the strap. This may eliminate or minimize the length of the lace that the lace securing device cannot secure to the non-fused area.

In other forms, the fused portion of the panel may be located between the base of the strap and the unfused region. This is illustrated by the portion of the fused region 41 between the ligament 302 and the unfused region 52 of fig. 17B.

The securing means of the strap end may be sized to span the gap between the strap base and the non-fused region when there is a fused region between the strap base of the headgear and the non-fused region to which the strap end may be connected. For example, in the configuration of fig. 17B, the lace securing device of the lace 302 can have a size along the length of the lace that is greater than the size of the fused region 41 between the base of the lace 302 and the unfused region 52.

Fig. 20 illustrates a configuration of a mold (e.g., an upper mold 503 or a lower mold 504 for fusing a headgear as shown in fig. 19) of the welding apparatus 500.

As shown in fig. 20, the mold 503 has a mold face 506 that corresponds to the size and shape of the desired fused region 41 of the headgear. A plurality of small circular areas 505 are recessed from the die face 506. At these recessed portions, the mold may not press the adjacent panel of the headgear too strongly or not press the adjacent panel of the headgear during fusing. This may result in one or both of the following: compression of the panel adjacent to the mold at the recessed portion is reduced; and the extent of welding of the one or more panels at the recessed portion is reduced or no welding.

Fig. 21 illustrates a further embodiment of a fused headgear, and fig. 22 illustrates an example of a mold 503 that may be used to make the fused headgear of fig. 21.

As previously described, the headgear may have one or more transition regions that fuse the panels. In the transition zone, the degree of fusion of the one or more panels may transition between the degree of fusion of the non-fused zone and the degree of fusion of the fused zone.

The transition zone may be located between the non-fused and fused regions.

In other configurations, the transition zone may be disposed within the unfused zone or within the fused zone, or between two unfused zones or between two fused zones. In such cases, the transition zone may define a partially fused region of one or more panels.

Fig. 21 shows a fused headgear 10 having a fused region 41 spanning the strap portion of the headgear and four unfused regions 51-54 at the strap connection portion of the headgear.

The headgear also has a set of second fused regions 42a-d arranged as clusters of small individual regions. These are in contrast to the unfused regions of the headgear of fig. 19, and instead define fused material points.

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

The second fused region 42 defines a point indent or recess in the headgear where the panels are compressed or thinned as they are fused.

As shown in fig. 21, the lateral second non-fused regions 42a and 42d have a triangular overall shape that tapers inwardly toward the central portion of the headgear. The base of the triangle is positioned adjacent to the respective strap connection portions 51 and 54, while the apex of the triangle is positioned away from the respective strap connection portions 51 and 54.

As shown in fig. 21, the narrowed portions of the second non-fused regions 42a and 52b are located within the transition regions 61 and 64, respectively.

The second non-fused regions 42b and 42c also have a generally triangular shape. However, unlike the second non-fused regions 42a and 42d, the second non-fused regions 42b and 42c are oriented such that their narrowed portions are positioned toward their associated strap connecting portions 52 and 53 and the opposite bottom portions are positioned toward the straps of the headgear.

As shown in fig. 21, the wider portions of the second unfused regions 42b and 42c are located within the transition regions 62 and 63, rather than the narrowed portions of the second unfused regions 42a and 42d being opposite their respective transition regions 61 and 64.

As shown in fig. 21, the second non-fused regions 42a and 42d have a greater size adjacent to their respective strap connection portions 51 and 54 than the second non-fused regions 42b and 42c adjacent to their respective strap connection portions 52 and 53.

The size of the fused region, which consists of smaller fused portions or clusters of points, may be larger or smaller than that shown in fig. 21. Similarly, the size of the smaller fused portions and their proximity to each other may be greater or less than that shown in fig. 21.

When smaller clusters of fused portions constitute the fused regions, the size and relative position of the fused portions to each other may be uniform or non-uniform.

Each smaller fused portion may be fused to the same extent, such as shown in the illustration of fig. 21. Alternatively, one or more of the smaller fused portions may be fused to a relatively greater or lesser extent. As with the transition zone, the degree of fusion of the smaller fused portions may vary over the fused zone consisting of clusters of smaller fused portions. For example, the degree of fusion may decrease toward one or more sides of the fusion zone, or may decrease toward the entire perimeter or perimeter of the fusion zone.

The size and shape of the smaller fused portions and their density and placement within the fused region 42 may provide a desired pattern or texture, such as for a headgear or for one or more portions of a headgear.

The configuration of the fused and unfused regions, particularly where a pattern of fused or unfused regions is used, can be used to customize and particularly localize the characteristics of the headgear (such as breathability), its absorbent capacity, its edge characteristics, feel, drape and its extensibility and recovery.

For example, clusters of fusion points may be used to impart a waffle texture to the headgear, particularly when fusion of the headgear compresses or thins the headgear at the fusion portion. Such a wafer texture may comprise a pattern of recessed dots. Similarly, clusters of non-fused spots may be used to impart a reverse waffle texture to the headgear.

The headgear of fig. 21 further has four transition regions 61-64. Each located between an associated one of the non-fused regions 51-56 and a portion of the fused region 41.

At each of the transition regions 61-64, the first panel 1 and the second panel 2 may be fused together to a degree that is between the degree of fusion of the fused region 41 and the degree of fusion of any of the unfused regions 51-54, as indicated by the lesser shadow density.

The transition zone may define a single degree of fusion, for example, where the panels are fused together with about half the peel strength of the fused zone.

The shape of the transition regions 61-64 may vary. As shown in fig. 21, the size of the transition regions 61 and 64 varies from a narrower, narrow at the more central portion of the headgear to a wider configuration at the non-fused ends. In contrast, as shown in fig. 21, the transition regions 62 and 63 have the widest dimension at the centermost portion of the headgear.

Alternatively, the transition zone may define a gradual change in the degree of fusion. For example, as shown in fig. 21, the transition zone 62 may have a first relatively lesser degree of fusion adjacent the non-fused zone 52 and a second relatively greater degree of fusion adjacent the fused zone 41.

The degree of fusion may be gradual or graded as it varies over the transition zone. The gradient may be continuous or may vary over the transition zone.

By using a transition zone, a smoothing effect may be provided between the characteristics of the adjacent fused and unfused zones, particularly when the degree of fusion varies over the transition zone.

For example, the transition zone may taper the transition between these different characteristics when one or more of the thickness, extensibility, recoverability, softness, or surface texture of one or more panels is changed by fusing. This may provide one or more of improved performance, increased comfort, or improved feel of the headgear.

The comfort and performance of the headgear may be particularly affected by the transition region of use. When the headgear is worn by a patient, variations between different areas of the headgear (e.g., the relatively less malleable and load-bearing portion of the headgear and the adjacent relatively more malleable portion) may cause a concentration of pressure at the dividing line. Even without causing pressure concentrations, sharp transitions between regions of different characteristics may create a pressure sensation to the patient along the dividing line.

In this way, the transition region may allow the variation in the characteristics of the headgear between two different regions to be gradual, and accordingly may provide increased comfort to the patient.

In use, load may be applied from the strap connection at the non-fused regions 51-54 and the load may be transferred to the headgear at the fused region 41 of the strap. Accordingly, the transition regions 61-64 of the headgear of FIG. 21 are located between the non-fused and fused regions, and as such may provide a gradual change in at least the extensibility of the headgear along the load transfer path.

The various versions of the headgear 10 of fig. 21 may be provided with or without one or more sets of second fused regions 42.

In the embodiment of FIG. 21, the set of second fused regions 42 may be used to tack together panels at the portion of the associated non-fused regions 51-54 and transition regions 61-64. This may prevent undesired separation of the first panel and the second panel.

The set of second fused regions 42 may additionally or alternatively act as transition elements effective to increase the density or average degree of fusion of the fused regions within the associated non-fused regions 51-54 and transition regions 61-64.

The headgear of fig. 21 may have one or more straps attached thereto. For example, the side straps 301-304 and possibly the top strap 200 may be attached to the headgear 10 at one or more of the strap connection portions 120.

The one or more straps may be attached to the panel of the rear portion of the headgear by any desired method, such as by fusing, by adhesive, or by using a securing device.

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

In particular, as shown in the configuration of fig. 21, one or more laces such as shown in fig. 11 may be sandwiched between the free ends of the first panel 1 and the second panel 2 at the non-overlapping regions 51-54, and the panels and laces fused together.

While the rear portion of the headgear is shown in fig. 21 as having been fused prior to attaching any straps, it should be understood that the step of fusing the straps to the rear portion may be combined with the step of fusing the face plate of the rear portion.

A welding die 503 for fusing the rear portion of a headgear similar to that of fig. 21 is shown in fig. 22.

As shown in fig. 22, the mold has a mold face 506 corresponding to the fused region 41. It also has four recessed areas 505 corresponding to the four non-fused regions 51-54. The transition regions 61-64 of the headgear are defined by sloped transition regions 509 of the mold that gradually change from the level of the recessed region 505 to the level of the mold face 506.

The set of second fused regions 42 is defined by a plurality of posts 507 that are located at the level of the die face 506 and are defined by recessed portions of the die.

The post 507 may rise up to the same level as the die face 506.

The post 507 may extend to a level between the recessed level 505 and the mold face 506.

The posts 507 may all have the same height. Alternatively, one or more of the posts may have different heights.

In particular, the height of the pillars may vary from the side of each second fused region adjacent to the unfused region to the side of each second fused region adjacent to the fused region. For example, the height of the post may increase toward the fused region, thereby increasing the degree of fusion at the post toward the fused region.

The transition region of the headgear may have a gradient of its degree of fusion in one direction, such as shown by transition regions 61-64 of the headgear of fig. 21. Here, the degree of fusion increases away from the adjacent unfused region and toward the fused region at the zone of the headgear.

However, it may be desirable to provide a gradient in degree of fusion starting from all adjacent portions of either or both of the unfused or fused regions.

Fig. 23 shows an example of a headgear 10 having a configuration similar to that of fig. 21, but wherein the transition regions 61-64 have a fusion gradient around their entire perimeter.

Fig. 24 shows a mold for manufacturing a headgear having the configuration of fig. 23. In fig. 24, the transition regions 509 each define a smooth curve of mold height between the recessed region 505 and the mold face 506.

Headgear made using such a mold may have increased comfort because all transitions between welded and non-welded portions of the headgear with its different characteristics may be gradual rather than abrupt.

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

Fig. 25 shows another mold for manufacturing a headgear. The mold 503 of fig. 25 additionally includes a set of marker features 508. The marker features 508 are a combination of regions at the die face 506, at the recessed height, and possibly at various transition heights therebetween. By a combination of such features, one or more indicia may be formed into the headgear when the panels are fused. The indicia may be identified from a combination of the resulting fused regions, unfused regions, and possible transition regions. For example, when the panel is made thinner at the time of fusion, the mark can be recognized in a combination of the relatively raised and lowered portions of the headgear.

When the color or surface texture of the panels changes as a result of their fusion, the indicia may additionally or alternatively be identifiable by the differences in these characteristics.

It will be appreciated that the marking features 508 of the mold will define the features of the resulting marking on the headgear in relief; the concave portion of the mold will define the relatively convex portion of the headgear and vice versa.

Fig. 26 shows a partial view of a fused headgear 10 having indicia 9 formed therein by fusing with a mold having indicia features 508, such as the indicia features of the mold of fig. 25.

As shown in fig. 26, the indicia 9 is defined by a non-fused region 51 and separate fused regions 41-43 which form the shape of the constituent letters or symbols of the indicia, in this case brands.

In other configurations, the indicia 9 may be formed without a circumferentially differentiated portion as the non-fused region 51 in fig. 26. In this case, the constituent letters or symbols of the indicia will be defined by the non-fused regions in order to distinguish the surrounding fused portions of the headgear.

The application of the indicia by fusing the panels may be provided as a separate step of fusing the panels to join them together.

In various embodiments, forming the indicia may be accomplished in the same step as fusing the panels together to join them together. This may allow for a simplified manufacturing process, as the marking need not be provided as a separate manufacturing step.

Although shown in fig. 26 as being centered in the central region 15 of the headgear 10 and within the fused region, it should be understood that the indicia 9 may be disposed at any desired location of the headgear. Similarly, the headgear may be fused to present indicia at one or both of the interior or exterior surfaces of the headgear.

In addition to or instead of forming the indicia by selectively fusing one or more panels, the indicia may be formed by selectively removing material of one or more panels.

For example, fig. 26-1A shows a headgear 10 that includes indicia 9. Fig. 26-1B shows a section through line A-A of fig. 26-1A. As shown in fig. 26-1B, the headgear has a first panel 1 partially overlapping a second panel 2 at a cross section. However, material has been removed from the first panel 1 to form the shape of the indicia 9. The first panel 1 and the second panel 2 have been fused together to define indicia 9 in relief through the removed material.

This configuration may provide a clearly visible marking, especially in case the first panel 1 and the second panel 2 have different colors or surface textures.

Fig. 27 shows another embodiment of a headgear 10 comprising fused indicia 9. The headgear 10 has non-fused regions 51 and 52 at strap connection portions 120a and 120b at the lateral ends of the headgear and is fused at two more central strap connection portions 120c and 120 d.

Above the lacing connection portions 120c and 120d are two large non-fused regions 53 and 54.

The mark 9 is located in the center of the overlap of the first panel 1 and the second panel 2, above the cut-away (cut-away) of the second panel 2.

As previously described, one or more straps may be attached to the headgear of fig. 27. When the first and second panels are fused together at the lower strap connection portions 120c and 120d, the fused panels may overlap and be fused together with the strap.

The panels forming the headgear may need to be placed in a specific position in the welding apparatus relative to each other and to the mold of the welding apparatus. This may be necessary to provide the desired configuration of the overlapping and non-overlapping regions of the headgear and to provide the desired location of the fused and non-fused regions.

Accordingly, it may be desirable to include one or more locating features on one or more of the panels to align one or both of them with each other and with one or both of the molds.

Fig. 28A shows an embodiment of a lay-up for a headgear before it is fused. The lay-up comprises a first panel and a second panel 2 which is completely overlapping. The first panel 1 comprises a number of alignment features 8 provided on the sacrificial portion 7 of the first layer.

The alignment features (holes in the embodiment of fig. 28A) may mate with corresponding features of one or more dies of the welding apparatus. This may allow the first panel to be placed in a desired position relative to the mold.

One or more of the panels in the lay-up may include such alignment features. For example, both the first panel 1 and the second panel 2 may include alignment features. The alignment features may be discrete or may overlap each other (such as when the panels overlap in their intended positions). For example, both the first panel and the second panel may have alignment features that coexist when the panels are positioned in their desired positions relative to each other. With this configuration, the panels may be positioned relative to the mold, and the panels may be positioned relative to each other.

In some forms, the sacrificial portion 7 itself may act as an alignment feature, for example by being aligned with a portion of one or more dies.

The sacrificial portion 7 will be separated from the one or more panels before the manufacture of the headgear is completed. The separation of the sacrificial portions may be performed, for example, by punching or cutting the sacrificial portions from the remainder of one or more panels.

In some forms, the sacrificial portions may be stamped to separate them from the panel, and the step of stamping may be combined with the step of fusing the panels together. To this end, the mould may comprise a cutting surface which may act on the panels when the mould is brought together to fuse the panels.

In other forms, the sacrificial portion may be separated during fusion of the panel by melting or burning of the panel, for example in the case of high frequency welding, by allowing an arc to be generated between the dies, wherein the sacrificial portion will separate from the remainder of the panel.

In some embodiments, the alignment features 9 may not be provided on the sacrificial portion removed from the layup, but instead be provided on or within the rear portion of the headgear itself. For example, one or both of the panels may include one or more holes for aligning the panels, and these holes remain a feature of the headgear when the headgear has been fused.

Fig. 28B shows the headgear 10 of fig. 28A after it has been fused and stamped. The headgear includes a primary fused region 41, a plurality of sets of welds 42, and four non-fused regions 51-54.

While stamping or cutting may be employed to separate the sacrificial portion from the headgear to facilitate alignment of one or more panels as previously described, other portions of the headgear may additionally or alternatively be stamped or cut.

Accordingly, the headgear may be cut or stamped to remove material. This may include one or both of the following: removing a peripheral portion of the one or more panels, and removing an interior portion of the one or more panels.

For example, a portion of the overlap region, and particularly a portion of the fused region of the overlap region, may be removed from the headgear. Removal of these portions may, for example, reduce the weight of the headgear. The removal of multiple portions may also improve the breathability of the headgear.

The cutting or punching of one or more of the panels of the headgear may also be configured to create one or more indicia, such as a make, model name or number, size information, serial number, regulatory information, or other such features.

Cutting or punching of one or more of the panels of the headgear may create the indicia by making one or more holes in the shape of the indicia through the headgear.

The mark may additionally or alternatively be formed by removing a portion of one layer at the overlap region. The mark may then be identifiable by the surface features of the headgear from which material has been removed. In the case of the overlap layer having a different color or texture, the indicia may be identifiable by the color or texture.

When the mark is cut or punched into one panel at the overlap region, a mark that is identifiable, or at least primarily identifiable, from only one side of the headgear may be provided. For example, where a panel at the interior surface of the headgear that will be closest to the user is stamped, while an adjacent panel or panels toward or at the exterior surface are not stamped, the indicia may be displayed only at the interior surface of the headgear.

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

A portion of the headgear may be removed in the same step as the headgear is fused, such as by headgear die cutting that occurs when fusion is applied.

In other forms, portions of the headgear may be removed after the panels are fused by die cutting or any other suitable method.

In forms where there is a fused perimeter of one or more overlap regions and the removal of a portion of the headgear occurs with or after the step of fusing the panel, the removal of material only within the fused region may maintain the fused perimeter of one or more overlap regions.

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

Fig. 40A shows the headgear 10 of fig. 17B coupled to a plurality of tethers 301-304 and 200. The headgear 10 of fig. 40A illustrates how the headgear may be punched through both the first layer 1 and the second layer 2.

As shown in fig. 40A, the headgear includes a cluster of first cuts 91 of a first size and a cluster of second cuts 92 of a second, larger size.

The cuts 91 and 92 of fig. 40A pass through both the first panel 1 and the second panel 2 to define a cut through the entire headgear.

Such cuts may reduce the weight of the headgear. They may also increase the breathability of the headgear.

The cutouts 91 and 92 of fig. 40A may be provided in each of the first and second panels, respectively, before the first and second panels are fused.

The cutouts 92 and 92 of fig. 40A may be provided into the first and second panels together prior to, as part of the fusing process, or after they are fused.

While fig. 40A illustrates the cuts at the lateral portions of the zone 110, it should be understood that the cuts may be provided at any desired location on the headgear, and particularly where it is desired to increase the breathability of the headgear. Similarly, it should be appreciated that individual cuts or clusters of cuts may be provided in any number of desired sizes and groupings.

Fig. 40B shows the headgear of fig. 40A, but with a different incision configuration. As shown in fig. 40A, the headgear has a plurality of first incisions 91 of the second layer 2. Within the first cutout 91 of relatively small size, there is then a corresponding second cutout 92 of the underlying first panel 1.

This configuration may provide increased weight savings relative to a smaller cutout 92 sized through-hole.

The configuration of fig. 40B may also provide localized areas of increased extensibility within each cutout 91 of the second panel 2 when the first panel 1 is more extensible than the second panel 2.

A larger cut may be made in the relevant panels before they overlap each other, while a smaller cut may be made through both panels before, during, or after the panels have been fused to each other.

Fig. 40C shows another embodiment of a headgear with a cutout. Fig. 40C shows the rear portion 100 of fig. 13, but viewed from the opposite side. For example, fig. 13 shows an exterior view of the headgear, while fig. 40C shows the interior of the headgear facing the patient.

In fig. 40C, the range of the second panel 2 stacked down is shown in broken lines.

As shown in fig. 40C, the first panel has a plurality of first cutouts 91. Within these first cutouts there is a second cutout 92 of the second panel 2 of smaller size. This is in contrast to the configuration of fig. 40B.

In fig. 40C, the cutouts 92 each define a hole through the headgear.

Also shown in fig. 40C are a number of third cutouts 93. These are incisions in the first layer 1 such that areas of the second layer 2 are exposed, but do not define holes through the headgear.

Headgear according to the present disclosure may provide one or more zones of extensibility 80. At the stretch region, the headgear may provide a relatively greater amount of extensibility than at an adjacent portion of the headgear. The shape, size and location of such stretch zones may allow the headgear to have custom functions. For example, the stretch zone may be oriented to allow the headgear to have additional extensibility in one direction but not in the other direction. The extension region may be configured to cause relative rotation of the headgear portions on either side of the extension region when a load is applied across the extension region.

Fig. 29 shows an embodiment of a headgear made by fusing a first panel and second, third and fourth panels 2a, 2b, 2c that overlap the first panel. Each of the second, third and fourth panels may be of the same material, or may alternatively be formed of two or three different materials.

The third panel 2b and the fourth panel 2c are located on the first panel 1, laterally spaced from the second panel 2 a. The gap between these panels defines a first extension 81 and a second extension 82.

At the stretch zones 81 and 82, the headgear consists of only the first panel 1. As described in various other embodiments, the first panel may be of the following materials: the material is relatively more extensible than the second (and third and fourth) panels, or at least the material is more extensible only at the non-overlap regions where the stretch zones are located than at the overlap regions where the panels have been fused.

As shown in fig. 29, the stretch zones 81 and 82 have a substantially continuous lateral dimension and extend across the entire height of the zones of the headgear.

When a load is applied to the headgear in the direction of arrows 801 and 802, the headgear may stretch and expand in that direction due, at least in part, to the expansion at stretch zones 81 and 82.

It may be desirable to provide different amounts of extensibility in different portions of the headgear to allow the headgear to stretch to a different shape than its flat-laid shape.

For example, it may be desirable that the headgear then be stretched, with the upper portion of the headgear being stretched relatively more than the lower portion of the headgear.

Fig. 30 illustrates an embodiment of the headgear 10 in which the two expansion zones 81 and 82 are configured to allow greater expansion toward the top of the headgear's zone than toward the bottom thereof.

As shown in fig. 30, the zones of extensibility 80 and 81 have a greater width toward the top of the zone than at the bottom. Accordingly, when a load is applied in the direction of arrows 801 and 802, the lateral ends of the headgear that are outside of the extension regions 81 and 82 may rotate in the direction of arrows 803 and 804 by at least some amount.

It may be desirable to allow more stretch at one portion of the headgear 10 to facilitate a particular movement of the patient. For example, when a patient wearing the headgear is low or raised, the distance between the top of the rear portion of the headgear to the top attachment point to the patient interface and the distance between the bottom of the rear portion of the headgear to the lower attachment point to the patient interface may vary unevenly. Accordingly, greater extensibility at the top or bottom of the headgear may be desirable.

Although fig. 30 illustrates a configuration in which the zones of extensibility have a stepped size along the lateral direction of the zones, zones of extensibility whose size varies continuously along the lateral direction of the zones may additionally or alternatively be provided. An example of this is shown in fig. 31, where the zones of stretch 81 and 82 are relatively narrow toward the upper portion of the band of the headgear and relatively wide toward the lower portion of the band of the headgear.

Since the extension area is wider at its lower portion, the lateral portions of the headgear may be caused to rotate at least slightly in the direction of arrows 805 and 806 when a load is applied in the direction of arrows 801 and 802.

The amount of allowable stretch of the headgear may be controlled by varying the size of the stretch zone and the stretch characteristics of the first panel 1.

The zones of extensibility may also be configured in a curved shape, such as shown by zones of extensibility 81 and 82 in fig. 32.

Fig. 33 shows a further embodiment in which the curved stretch zones are oriented opposite to the stretch zones of fig. 33, the stretch zones 81 and 82 being curved toward the center of the headgear.

In fig. 33, unlike fig. 32, the extension regions 81 and 82 are also larger in lateral dimension toward the center thereof than at the upper and lower ends thereof. This may allow for a relatively large degree of stretch in the middle of stretch zones 81 and 82.

While the foregoing examples have shown an extension region that extends vertically across the entire height of a portion of the headgear to allow the headgear to extend laterally, the extension region may also be arranged laterally across the headgear to allow the headgear to extend vertically.

For example, the stretch zone may be disposed laterally across the fused region of the headgear adjacent to the lower strap connection portion. This may allow for additional vertical extension in the headgear when a load is applied to the attached strap.

The headgear may include one or more zones of extensibility. As shown in the configuration of fig. 29-33, these zones of extensibility may bisect the fused portion of the headgear, resulting in multiple separate zones of fusion.

However, in other configurations, an extension region that does not bisect the fused portion of the headgear may be provided such that the fused region of the headgear is one continuous region.

Whether or not the headgear includes one or more zones of extensibility, the headgear may have one or more continuous zones of fusion between two or more strap attachment portions of the rear portion of the headgear. The continuous fused area between the two strap connection portions may facilitate efficient transfer of load through the headgear when load is transferred between the straps of the headgear in use.

For example, the rear portion 100 of fig. 14 has a continuous fused area of the first and second panels within the fused region 41 between the lateral lacing connection portions 120a and 120 d. In fact, in the configuration of FIG. 14, the rear portion 100 defines a continuous region of the fused region 41 between the various belt connecting portions 120 a-d.

The faceplate of the headgear may be configured to impart a particular overall shape or structure to the headgear such that it may have such a shape or structure when not being worn. The shape may be created from an existing 3D shape of the panel prior to fusing, or by fusing of the panel, or both.

Such a shape or structure may be important for informing the patient or informing the person applying the headgear to the patient about the nature of the respective parts and their intended direction of wear. For example, it may be desirable for the headgear to have an opening between the straps on each side when in rest, within which the patient's head may be received. Similarly, it may be desirable for the headgear to present the side straps as distinct members when in rest, such that they extend from the remainder of the headgear and potentially also independently of each other, to allow the patient to easily identify and grasp each strap so that the straps may be connected to the patient interface.

Such a shape and configuration may be present, for example, when the headgear 10 is held by a patient, or particularly when a portion of the headgear is held by a patient and the remainder of the headgear hangs down or hangs from the held portion.

Where the headgear or a portion of the headgear includes two or more overlapping panels, the edges of one or more of the panels may extend past the adjacent edges of one or more other overlapping panels. An example of this is described previously with respect to fig. 13, in which the first panel 1 beyond the second panel 2 is not overlapped and supported by the second panel 2. This configuration may allow the contact pressure on the patient's head to gradually decrease from the edge of the overlap of the first panel 1 and the second panel 1 to the furthest non-overlap of the first panel 1 when worn. This may provide the patient with an edge softening effect when wearing the headgear.

Fig. 34 illustrates a headgear 10 having such edge softening characteristics along at least a portion of the upper edge of the rear portion. The rear portion 100 of the headgear 10 includes a first panel 1 and a second panel 2. The portion 1a of the first panel 1 at the rear portion 100 extends past the upper edge of the second panel 2. The portion 1a of the first panel 1 does not overlap the second panel 2. With this configuration, the first panel 1 defines an upper edge 401 of the rear portion 100 of the headgear that surrounds at least a portion of the rear of the patient's head.

As shown in fig. 34, the top strap 200 is attached to the rear portion 100, and the portion 1a of the first panel 1 also extends beyond the upper edge of the top strap 200.

The overhanging portion 1a of the first panel 1 may provide an edge softening effect for the patient when wearing the headgear.

As shown in fig. 34, the first panel 1 including the overhanging portion 1a is disposed inside the top strap 200 with respect to the patient's head. As such, when the headgear is worn, the overhanging portion 1a will roll away from the patient's head and preferably over the top strap 200.

The panel having the non-overlapping peripheral portion may be at least one of: thinner, softer and less dense than the headgear panel or the portion overlapping it (e.g., top strap 200 in the case of fig. 34).

Although described with respect to forming a pressure gradient edge at the upper side of the rear portion 100 of the headgear, the described techniques may be applied to any other portion of the headgear to achieve the same functionality. For example, such a panel configuration may be used at the lower periphery of the rear portion 100, and/or the ear loops 320.

The faceplate of the headgear may be configured to impart a particular overall shape or structure to the headgear such that it may have such a shape or structure when not being worn.

Such a shape or structure may be important for informing the patient or informing the person applying the headgear to the patient about the nature of the respective parts and their intended direction of wear. For example, it may be desirable for the headgear to have an opening between the straps on each side when in rest, within which the patient's head may be received. Similarly, it may be desirable for the headgear to present the side straps as distinct members when in rest, such that they extend from the remainder of the headgear and potentially also independently of each other, to allow the patient to easily identify and grasp each strap so that the straps may be connected to the interface.

Fig. 35 illustrates a headgear 10 configured to display a certain shape and form when not worn. The headgear 10 may have a top strap 200 that is sufficiently stiff to maintain it in an at least partially rounded form when in rest. This is illustrated in the example of fig. 35, wherein the remainder of the top strap 200 hanging from the patient's hand assumes a substantially circular form.

The manner in which the straps 300 may extend away from the remainder of the headgear 10 and also extend discretely from one another is also seen in fig. 35. To provide such a configuration, one or more panels of material (which includes the lace 300) may be provided with sufficient rigidity to hang down with a sufficiently low amount of curvature over its length. Additionally or alternatively, one or both of the rear portion 100 and/or the top strap 200 to which the strap 300 is attached may bias the straps to drop outwardly away from each other and from the remainder of the headgear 10.

To achieve such a configuration, the strap 300 and/or the panel of the remainder of the headgear that overlaps the strap may be provided with a natural curl or curve.

In some embodiments, the base panel may overlap with a more peripheral stretchable panel that is pre-stretched when fused to the base panel. This may induce a natural curvature in the fused panel to provide a desired natural shape and/or disperse the tethers 300 away from each other.

In addition to or in lieu of providing the headgear with an idle shape to inform the patient about the nature of the different portions or any panel configuration used or applied thereto, the headgear may also be configured to inform the patient about these things visually or through tactile cues.

For example, referring to the headgear 10 of fig. 35, the top strap and rear portion of the headgear may be provided with one color or predominantly one color. One or more of the straps 300 may be provided with a different color and/or texture than the top strap 200 in order to be easily distinguished from the rest of the headgear. As shown in fig. 35, the upper tethers 301 and 303 may be provided with a different color and/or texture than the lower tethers 302 and 304. Any such structural, visual, and/or tactile cues that may be built into the headgear may additionally or alternatively be utilized to assist the patient in distinguishing between the interior surface 5 and the exterior surface 4 of the headgear 10.

For example, some or all of the panels including the inner surface may be provided with one or more different colors than some or all of the panels including the outer surface 4 of the headgear.

In other configurations, some or all of the panels comprising the headgear interior surface 5 may have a different texture than some or all of the panels defining the exterior surface 4. In particular, the texture of the inner surface 5 may be partially or fully softer than the outer surface 4 to help inform the patient that the portion should be close to his head and provide enhanced comfort when worn.

As shown in fig. 36A and 36B, the location of the junction 572 between the rear portion 100, the top strap 200, and the side straps 300 may be configured to be located over the ears of the patient.

The side strap 300 of the headgear 10 may include one or more strap panels that are fused together.

The ends of the side straps of the headgear may be passed through a securement device on the respiratory interface and folded back onto itself and secured to itself. To achieve this, a two-part fastener system, such as a hook and loop fastener, may be provided on the side tie.

However, when tightening the side straps themselves in opposite directions, it may be desirable to provide some form of feedback to the patient as to how tight the cover is, and/or to provide some conventional step in which the straps may be adjusted to help easily equalize the amount of tightening of the different straps.

Fig. 37A shows a guide (index) panel 335 to be fused to the base panel 310 to form a side tie. Guide panel 335 includes at least one series of stepped structures 337 extending at least partially between the sides of guide panel 335.

The guide panel 335 may include a relatively stronger, stiffer, denser, and/or harder material than the underlying substrate panel 310 to which it is to be fused.

Fig. 37B illustrates the guide panel 335 of fig. 37A fused to the base panel 310.

By positioning the guide panel 335 on the exterior surface 15 of the headgear relative to the base panel 310, the guide panel 335 can contact the securement device of the respiratory interface as the strap end passes through the securement device and pulls back toward the rear portion 100 of the headgear.

The stepped structure 337 of the guide panel 335 may provide tactile feedback to the patient when the harness 301 is tightened over the respiratory interface when tension is present on both sides of the harness on the respiratory mask securement device.

An additional function of such a guide panel 335 (which is a relatively stronger, stiffer, denser, and/or harder material than the base panel 310) may be to provide abrasion resistance to the harness 301 as it engages and passes through the securement of the respiratory interface. For this purpose only, the lace may include a guide panel 335 without a defining cutout 336 for providing tactile feedback, but may alternatively have a guide panel 335 without a cutout.

Fig. 38 shows an additional configuration of side tie 301 that includes a base panel 310 and an index panel 335 fused thereto.

As shown in fig. 38, the distal portion of lace 301 has a first portion 331 of the fastener system within the cutout of guide panel 335 that corresponds to a second portion 332 of the fastener system. The second portion 332 may be provided by the material of the base panel 310 itself, or by another material fused thereto.

Although shown in fig. 37A-37B and 38 as including a unitary panel having a plurality of cutouts 336 to define a stepped structure 337, according to other embodiments, the guide panel 335 may be provided as a stepped structure 337. In other words, the guide panel 335 may alternatively include a plurality of step structures 337 without any linking material to define a single unitary panel.

The stepped structure 337 may present a raised surface above the surface of the underlying lace panel such that the stepped structure provides resistance to movement of the lace relative to the interface. The spacing of the stepped structures may provide an indication of the patient's direction for each strap as the patient adjusts the tension on the headgear straps.

To provide indexing resistance, the stepped structure 337 may be a material different from the underlying lacing panel and possibly harder or denser.

Fig. 39A and 39B illustrate an example of such a lace end feature 350. As shown in fig. 39A, the lacing end feature 350 includes a first tab panel 351 that at least partially overlaps the lacing panel 310. As shown in fig. 39A, the first tab panel 351 has a greater surface smoothness than the lacing panel 310, and thus may be distinguishable from it by touch.

The first portion 331 of the hook and loop fastener is atop the first tab panel 351. In some embodiments, the outer surface of the lacing panel 310 can form a second portion 332 of a hook and loop fastener to engage the lacing end as the lacing end is folded back upon itself.

As seen in the configuration of fig. 39A, the lacing panel 310 includes a second half 332 of a hook and loop fastener. For example, the lacing panel 310 may be a complete loop material, and loops present at the surface of the lacing panel 310 may be used as loops of hook and loop fasteners.

The lacing panel 310 may overlap the first tab panel 351 alone, or it may overlap the corresponding second tab panel 352 on the other major face thereof, as illustrated in the side view of fig. 39B.

While the presence of the first tab panel 351 and/or the second tab panel 352 may provide a desired degree of ability to distinguish the end of the tie from the rest of the tie, an adhesive may be utilized to enhance such differentiation. For example, the adhesive may provide increased rigidity to the lace end feature 350 relative to the lace panel 310. This difference in stiffness can create additional physical cues to the patient regarding the presence of the strap end.

The first tab panel 351 and the second tab panel 352 may be fully overlapped on the lacing panel 310 to provide a three panel lay-up, as shown in the first overlap region 21 of fig. 39B.

In other configurations, tab panels 351 and 352 may extend distally from the end of lacing panel 310 (as seen in fig. 39B) to form second overlap region 22.

The difference in thickness between the first overlap region 21 and the second overlap region 22 may provide additional tactile cues to the patient regarding the position of the lace ends.

Where tab panels 351 and 352 include a second overlap region 22 (where they overlap one another only singly, rather than overlapping both sides of lacing panel 310), additional amounts or different types of adhesive may be utilized at second overlap region 22. This may provide the second overlap region 22 with increased rigidity relative to the first overlap region 21 or the lacing panel 310 itself, and may be another potential form of prompting the patient that he is grasping the tab end.

Fig. 41 is a view of the upper portions of two different configurations of headgear 10a and 10b stacked on top of each other. The two headgear each have a different configuration of their top strap 200.

The first configuration 10a has a top strap 200a and the second configuration 10b has a top strap 200b. The top strap 200b is oriented to protrude laterally outward less than the top strap 200a, but rather extends primarily upward. In fig. 41, the top strap 200a is oriented as a substantially continuous extension of the adjacent portion of the rear portion 100.

As shown in fig. 41, the top strap 200a extends laterally outward at an angle of about 35 degrees from horizontal. The second configuration with the top strap 200b projects at a steeper angle to the horizontal, approximately 70 degrees from the horizontal.

The angle of the top strap 200 of the headgear relative to the lateral axis of the headgear can affect the position of the top strap on the patient's head in use. In some configurations, it may be desirable for the top strap to span the patient's head vertically and laterally in use with minimal or no proximal or distal displacement between the base and end of the top strap.

Wherever the straps span the patient's head, it may be desirable to select the angle of the top strap relative to the lateral axis of the headgear so that the top strap lies flat on the patient's head to improve comfort.

In use, the more steeply oriented top strap 200b of fig. 41 will traverse the patient's head more forward than the more shallowly oriented top strap 200 a.

The manufacture of headgear according to the present disclosure may involve fusing a portion or all of the headgear. Although various discrete fusion processes are described elsewhere herein (such as with the press welder of fig. 9A and 9B), fusion may additionally or alternatively be provided as a continuous process.

For example, fig. 42 illustrates a continuous welding operation in which two panels 511 and 512 are continuously welded together using two rollers 510. Such a process may be desirable for increasing manufacturing speed, and may be particularly suitable for continuous shapes, such as welding lengths of panels, which may then be cut into sections for use as headgear straps.

The continuous welding process may also be used to form one or more folded edges of the headgear, such as described in further detail later, for example, with respect to fig. 63-67. Fig. 42 illustrates an example of a continuous fusing operation to form a headgear portion having folded edges, wherein a roller 510 is used to continuously fuse together a first panel 511 and a second panel 512 along the edges of the first panel 511, each edge of the first panel being folded back onto the second panel 512.

Although the continuous welding process may be applied to one or more panels having a continuous width, the width of the panels may vary.

While fig. 42 illustrates a continuous welding process performed in a plane, the continuous welding operation may be performed in other configurations (such as where one or more panels are wrapped concentrically and a screw joint is welded). An example of this is shown in fig. 43, where the panel 511 is wrapped in a tube shape, and the rollers 510 weld at least the overlapping portions to fuse them together and hold the panel 511 in its tube shape.

Headgear according to the present disclosure may be fused using one or more different fusion methods. For example, fusion may be provided by one or both of a discrete process and a continuous process. The fusion may be applied using only one type of fusion process (such as high frequency welding), or a variety of different processes (such as both high frequency welding and direct thermal welding) may be applied to the same or different portions of the headgear.

The continuous welding process may also be used to define fused and unfused areas of the panel between the rolls, or by using recessed areas of the welding rolls to provide varying degrees of fusion in a similar configuration as described with respect to the mold of fig. 20.

Fig. 44 is an example of a continuous welding process in which two rollers 510 each include a pattern of recessed areas 513 such that the panel 511 is provided with a corresponding pattern of non-fused areas 514 upon welding. One or more panels to be fused may be pre-stretched prior to fusion. The combination of pre-stretching and fusing may be used to render the planar panel into a 3D shape. For example, the panel may be stretched and then only a portion thereof fused. When the tension is released, the fused portion may recover less stretch than the unfused portion. This may cause the panel to assume a 3D shape.

The pre-stretch may be used in a discrete fusion process or a continuous fusion process. Fig. 45 illustrates a continuous welding process using two rollers 510 that each act as a welding die to weld one or more panels 511, wherein the panels are pre-stretched by multiple sets of auxiliary rollers 515.

The pre-stretched panel or group of panels may overlap another panel or group of panels that is not pre-stretched, and the overlapping panels may then be welded together. The panel may be twisted into a desired 3D shape using a pre-stretch at one side of the overlapping panel set.

According to various configurations, it may be desirable to form a pocket or void between two panels to be welded together. Such pockets or voids may be formed by selectively not fusing the overlap areas where voids are desired.

One or more inserts 520 may be used to form the bag or void where additional volume is desired, and/or where the panel is desired to have fused material properties such as surface finish or rigidity at the bag or void.

Fig. 46-1A shows two inserts 520 disposed on top of the first panel 511. The inserts 520 are shown as having a rectangular cuboid shape, but it should be appreciated that they may be of any desired shape as required to impart the desired shape to the pocket or void.

In fig. 46-1B, the second panel 512 has been overlaid on the first panel 511, and the two panels have been fused together, then the insert 520 has been removed through the open and unfused side 521.

The second panel may optionally be stretched over insert 520 prior to fusing the panels.

As shown in fig. 46-1B, the fused second panel 512 retains a 3D shape to define two pockets 521.

Once the insert 520 has been removed, the non-fused side 521 may then be fused or otherwise closed (if desired) to close the bag and form it into a closed interior void within the panel.

Where fusion is applied across inserts 520, these inserts may be made of non-fusible materials. For example, in the case of high frequency welding, they may not include dipole materials. Alternatively, in the case of direct thermal welding, their melting point may be higher than the welding temperature.

Fig. 46-2 shows the first panel 1 partially overlapping the second panel 2. The overlap region 21 has been fused leaving a series of voids 530 within the overlap region 21 where the first panel 1 and the second panel 2 are not fused together.

Fig. 46-3 shows another configuration in which the first panel 1 and the second panel 2 have been fused together along two opposite sides leaving a continuous pocket 530 extending along the length of the two overlapping panels.

According to some embodiments of the present disclosure, a fused panel of a headgear may be used to define an air duct. An example of such a configuration is shown in fig. 47A, where the headgear 10 defines an air conduit 522 in each of its two side arms or side straps 301 and 302. The front portion of each side arm is connected to the patient interface 600. Then, as shown in fig. 47A, external conduits 601 and 602 may be attached to the more rearward portion of the headgear at the rear of each strap 301 and 302. In other forms, the air conduit of the headgear may extend into the rear portion or top strap of the headgear, and one or more external conduits may be attached at one or more locations on the rear portion or top strap of the headgear.

By selectively leaving a portion of the headgear unfused, an air conduit may be formed in the headgear. Fig. 47B shows a cross-sectional view through line A-A of fig. 47A. In fig. 47B, the first and second panels 511 and 512 have been fused together along their edges 821 and 822, but the central portion is left unfused to define the air duct 522.

In addition to leaving unfused, inserts (such as insert 520 described with respect to fig. 46-1A and 46-1B) may also be used to form air ducts.

The pockets in the unfused region of the headgear may be accessed by overlapping the unfused perimeter of the panel, as shown in fig. 46B. The bag may also be accessed through a cut in one of the panels that would otherwise be completely fused together at the perimeter of the panel.

The headgear pocket may be used to receive and retain an insert, such as a reinforcing insert.

The bag may also be used in the manufacture of headgear where the headgear is assembled in multiple steps. For example, fig. 48A-48D are steps in a process for attaching a strap to the rest of a headgear by inserting the strap into a pocket of the headgear.

Fig. 48A illustrates a portion of the rear portion 100 of the headgear 10 that includes a strap connection portion 120. The rear portion 100 has a first panel 1 and a second panel 2 partially overlapping the first panel 1. The second panel 2 includes a cutout 530. In fig. 48A, the first panel 1 is visible through the cutout 530 of the second panel 2.

The overlapping first and second panels are then welded to each other around their perimeter, as shown by the fused region 41 of fig. 48B. Fusion around the perimeter forms a pocket 531 between the first panel and the second panel, which is accessible through the cutout 530.

When the first and second panels are joined to one another, the ends of the tie 300 are inserted into the pocket 531 through the cut-out 530, as shown in 48C.

The lace ends can have the same size as the remainder of the lace, or as shown in fig. 48C, the lace ends can have a reduced size.

When the tie ends are inserted into the bag 531, the bag and tie ends can be fused to secure the tie to the first and second panels. Fig. 48D illustrates the arrangement after the portions have been fused across a portion of the bag, thereby defining the fused region 42.

Assembling the straps to other panels of the headgear by inserting one portion into the pocket of another portion may limit the likelihood of misalignment of the portions during assembly. For example, as in fig. 48A-48D, only the end portion of the lace 300 is sized to be received through the incision 530. The use of a bag to provide such physical restraint may simplify manufacturing as compared to other methods, such as joining a strap or other panel by sandwiching the strap or other panel between loose ends of two other panels.

In an alternative configuration, the tie and rear portion may be joined as shown in fig. 48A-48D, but without the cut 530 of the second panel 2 by leaving the perimeter portions of the first panel 1 and second panel 2 adjacent to the tie non-welded in the second step. The tie 300 may then be inserted through the open perimeter into the pocket 531, and the components welded together.

As previously described, selective fusion of different regions of the panel or panels can be employed to provide desired characteristics to the headgear or portion of the headgear. These features may include texture, thickness, stretch properties, or surface properties (such as UBL properties).

This selective fusing may be performed in areas where the entire portion of the headgear may be fused while the other portions remain unfused. For example, as shown in fig. 14, the entire overlap region 21 may be fused while the entire non-overlap region 32 is left unfused. Alternatively, as shown in fig. 48B-48D, the perimeter of the overlap region, or a portion thereof, may be fused, leaving the non-overlap region, as well as the inner portion of the overlap region, unfused.

Selective fusing may additionally or alternatively be performed to provide a fused or unfused region of the pattern, such as that already described with respect to fig. 21 and 19, respectively.

As previously described, according to some configurations, the headgear may meet a straight line test at one or more locations such that the weld length is greater than the non-weld length along a straight line drawn between two edges of the headgear and more particularly between two edges of the overlap region of the headgear.

Fig. 14 shows the rear portion 100 of the headgear meeting the straight line condition along any straight line drawn between the two edges of the overlap region 21.

Although the overlap region 21 of the rear portion 100 of fig. 14 is fully fused, the straight line test may be satisfied in other configurations where the overlap region is not fully fused. For example, in the configuration of fig. 19, the size and spacing of the fused regions 53 may be arranged such that the straight line condition may be satisfied along one or more lines drawn between locations along the upper and lower edges of the overlap region of the first and second panels.

Fig. 49A is a view of an example panel 1, and fig. 49B-49D illustrate examples of different fusion arrangements or patterns that may be provided to one or more panels having the size of the example panel 1.

Fig. 49B shows an array of spaced circular fused regions 41 within unfused peripheral region 31.

Fig. 49C shows the same array of fused regions 41 as in fig. 49B, but with the fused regions being smaller and denser than the configuration of fig. 49B.

The fused configuration of fig. 49B and 49C may reduce stretching of the panels fused in this manner. However, due to the symmetrical arrangement of the fused regions in each direction, the stretch characteristics in the directions of each of arrows 808 and 809 in fig. 49B and 49C will change to the same extent.

However, in some configurations, it may be desirable to provide directionally varying extensibility characteristics by selective fusion.

Fig. 49D shows another pattern in which fusion may be applied, wherein the density of fused areas decreases in rows along the panel. Such a configuration may provide uniform extensibility characteristics across the panel in the direction of arrow 808 when the panel is extended in the direction of arrow 809, but non-uniform extensibility characteristics in the direction of arrow 809 when the panel is extended in the direction of arrow 808. When stretched in the direction of arrow 808, the degree of stretchability will increase toward the lower portion of the panel as the density of the fused regions in the direction of stretch decreases.

Accordingly, with such a configuration, the directional stretch characteristics of a single panel or panel composite may be locally controlled. This may allow stretching to be provided only in the desired area, in the desired direction, and to a desired extent.

By selectively fusing the headgear, the characteristics of the panel or overlapping panel regions can be altered without the addition of other materials or fixtures. This may allow for the manufacture of headgear with highly tailored and localized properties from a single panel with uniform properties or from overlapping combinations of multiple panels (each with uniform properties).

Fig. 50 shows a harness strap 300. The ligament has a fused region 41 defining a bifurcation area toward where the ligament splits into two portions 300a and 300 b. The bifurcated nature of fused region 41 will allow strap portions 300a and 300b to open away from each other in the direction of arrow 811, but a continuous fused region from the laceration of the strap in the direction of arrow 812 toward end 300c thereof will resist or prevent stretching in that direction.

Fig. 51 shows another similar configuration, but wherein the lace 300 is fused to define a first fused region 41 toward the lace end 300c, and then a reduced amount of fused region toward the crotch of the lace and along each portion 300a and 300 b. This configuration will provide a similar function as described with respect to fig. 50, but due to the discontinuous nature of the fused region 42 in the direction of arrow 812 in the region proximate the bifurcation, the lace will have an increased amount of stretch at that region in the direction of arrow 812.

Although described with respect to a harness, it should be understood that the same concepts described with respect to fig. 50 and 51 may be applied to other portions of a headgear.

For example, fig. 52 shows the rear portion 100 of the headgear 10 and the vicinity of the two tethers 301 and 302. The rear portion 100 and the tethers 301 and 302 may be formed from a single panel or a combination of panels. As shown in fig. 52, the rear portion 100 and the tethers 301 and 302 have been fused to define fused regions 41 and 42, with the tethers fused along their lengths and the fingers of the fused regions extending from each of the tethers 301 and 302 into the rear portion. Each fused finger tapers in size toward its tip.

This configuration may gradually limit the extension of the rear portion 100 in the direction of arrow 812 toward its lateral sides while allowing extension at the middle of the rear portion. However, the fused fingers may have a less pronounced effect on the extension of the rear portion in the direction of arrow 812, as unfused material between the fingers will allow extension in that direction.

Fig. 53 shows a rear portion 100 having a fused region 41 extending continuously from one lateral side to the other lateral side of the belt 110 and a fused region 42 extending in a continuous line from the belt connecting portion 120 to the central portion of the belt 110. This configuration may provide increased stiffness and the ability to transfer loads along the direction of the continuous portions of fused regions 41 and 42, but still allow for stretching in the vertical direction. For example, the headgear may resist stretching in the lateral direction of the zones more than the height of the cross-zone 110.

Fig. 54 shows another headgear 10 when worn by a patient. Headgear 10 has a rear portion 100 with a fused region 41. The fused region 41 comprises a continuous portion towards the top of the rear portion, followed by three triangular portions, each of which tapers towards the bottom of the rear portion.

Due to the configuration of the fused region 41, the headgear 10 may limit lateral expansion toward the top of the rear portion, but increasingly allow expansion toward the bottom of the rear portion 100.

Fig. 55A-55C illustrate additional examples of how selective fusion of panels may provide directionally different stretch properties.

As shown in fig. 55A, the panel 1 has been fused to define two fused regions 41 and 42. In the example of fig. 55A, the two fused regions are in the shape of mirror image "T".

These fusion areas define a continuous fusion of the panels along a first diagonal of the panels in the direction of arrow 813, but have a gap of unfused panels between the two fusion areas 41 and 42 along the other diagonal in the direction of arrow 814.

Although illustrated using "T" shaped fused regions, it is understood that the directional stiffness of the first lateral direction 813 relative to the second lateral direction 814 may be provided by two parallel and adjacent portions of these "T" shapes extending along the direction 813 without legs extending along the direction 814.

In the configuration of fig. 55A-55C, when the panel is stretched along the diagonal of arrow 814, the portion of each "T" shape that extends in the direction of arrow 814 may provide in-plane twisting of the panel. As shown in fig. 55C, the arms of the "T" shape extending in direction 813 may bend toward each other when stretched along arrow 814.

While the use of reverse folded "T" shaped fusion zones in fig. 55A-55C exhibits directionally different stretch characteristics, it should be understood that the shape and orientation of the fusion zones may be designed to provide the desired directional stretch characteristics or to produce other desired in-plane deformations under stretching.

It is well known that some full face masks may tend to migrate upward over the patient's face when worn by the patient. By using panels with directionally different extensibility characteristics, ties that resist extension in the direction of migration can be manufactured. Such a configuration may help prevent migration of the mask over the patient's face while maintaining stretch in other directions in which stretch may still be desired. For example, by employing selective fusion to provide directionally different stretch properties, the headgear strap may be manufactured with reduced stretch transverse to its length, but not in a direction along its length.

Furthermore, it should be appreciated that by controlling the orientation of the fused regions (such as the "T" shaped fused regions 41 and 42 of the configuration of fig. 55A-55C), the direction of stretch and the direction of non-stretch of portions of the headgear may be locally redirected. For example, different portions of the headgear strap may allow or resist stretching in different directions.

While shown in fig. 55A-55C as using only two fused regions, it should be understood that a similar pattern of small fused regions may be used over a larger area of one or more panels.

The pre-stretching of the panel may be combined with fusing to create the surface features of the headgear.

An example of such a configuration is shown in fig. 56A and 56B. In fig. 56A, a panel 1 is shown that has been pre-stretched in the direction of arrow 815 before being fused to define the pattern of fused regions 41-44. After fusing, the stretch is removed and the panel is allowed to shrink in the direction of arrow 816. As the fused portions move toward each other, they may cause unfused portions of the panels to bunch together. This is shown in fig. 56B, where the panel has been restored in the direction of arrow 816 and a bunch 540 of panels has been formed.

While fusion of the panels may be used to alter material properties (e.g., stretch properties), to alter surface properties, or to create surface features (e.g., bunching 540), fusion may also be used to provide structure to the headgear.

As the degree of fusion increases, the fused panel or panels may become more plasticized and more rigid. Accordingly, fusion of one or more panels may be used to provide structure for a headgear.

Any such additional structure provided by the fused region may allow for a reduction in the size and volume of the headgear.

The headgear may be provided with structure by fusing the panels or by fusing another element (such as a solid plastic) to one or more panels of the headgear.

Fig. 57 shows the headgear 10 with the interface 600 secured to the face of the patient 700. The headgear 10 has three discrete fused structures 45-47. Each of these fused structures is relatively more rigid than the surrounding headgear and serves to transfer loads between different portions of the headgear while maintaining the desired shape of the headgear.

The first fused structure 45 provides rigidity between the rear portion 100 and the top strap 200. The second fused structure 46 provides rigidity between the top strap 200 and the upper strap 301. The third fused structure 47 provides rigidity between the rear portion 100 and the lower belt 302.

The first fused structure 45 may help prevent the posterior portion 100 from migrating up or down on the patient's head. Similarly, each of the second 46 and third 47 fusion structures may resist upward or downward movement of the harness, which in turn will prevent up and down migration of the interface 600 on the patient's face.

Although shown as three discrete structures in fig. 57, in other configurations, the three fused structures 45-47 may be provided as a single continuous structure.

Such a fused structure provides the headgear with a structure that can allow the headgear to be shaped and positioned in different configurations on the patient's head. For example, they may allow the posterior portion to be positioned higher on the patient's head, away from their neck, without causing the headgear to twist.

Fig. 58 illustrates an embodiment of the headgear 10 with the nasal interface 600 secured to the patient's face. The headgear is configured such that the rear portion 100 is located at a higher position on the rear of the patient's head than the headgear 10 of fig. 57.

Because of the higher position of the rear portion 100, the lower strap 302 must extend downward and around the patient's ear to avoid interference with it. The first fused structure 48 provides rigidity to the rear portion 100 and the underside tie 302 around the rear of the patient's ear. Similarly, the upper lace 301 is not connected to the rear section 100 in a straight line, and thus the second fusing structure 49 provides rigidity between the two sections.

As shown in fig. 58, in addition to or instead of allowing the rear portion 100 to be repositioned more upward on the rear of the patient's head, the use of a fused structure may allow the headgear to be reconfigured farther from the patient's ear or a portion of the ear thereof. This may allow the headgear to fit a wider range of people without interfering with their ears and may provide additional comfort because the headgear may be adjusted by the patient to a wider range of positions without touching their ears.

As shown in fig. 58, the headgear is shaped to provide additional clearance from the patient's ear, particularly in the area above and behind the patient's ear, as compared to the headgear of fig. 57.

The use of a fused structure may enable a reduction in the number of straps used to connect headgear 10 to patient interface 600. For example, fig. 59 shows a side view of the headgear 10 connected to the interface 600 by a single point. The headgear may include portions on either side of the patient's head, but the use of highly reinforced fusion structures 45 may facilitate only a single connection point between the headgear 10 and the interface 600.

Such fused structure 45 may be formed from highly fused panels and in particular textile or fabric panels. They may additionally or alternatively be formed of a rigid material fused to the underlying panel or panels.

In addition to being used to process or join panels together to form headgear, fusion may also be used to join other securing devices to headgear. This may include the case where the fused structure is to be provided by a rigid material fused to the underlying panel or panels. It may also include the case where an attachment fixture (such as a clip, clasp or hook and loop pad) is included as part of the headgear.

Fig. 60A shows a side view of the headgear 10 having a rear portion 100 and a single strap 301 and 302 on each side of the headgear. The headgear 10 is connected to the interface 600. The fixture 550 has been fused to the panel of the rear section 100.

The securing device 550 includes a slot through which the side strap may be folded back onto itself and secured to itself.

Fig. 60B shows a partial cross-sectional view through line AA of fig. 60A, showing the securing device 550 and the slot allowing the lace to pass through. The rear portion 100 of the headgear includes a first panel 1 and a second panel 2 at the fixture 550 that overlap each side of the fixture 550 and are secured thereto.

The fixation of such fixation means may be performed by fusion. The fusing process may be the same or different from the process used to fuse the headgear panel. The securing means may be secured simultaneously with the fusing of the headgear panel or in a separate step.

For example, in the case where the headgear panels are fused by high frequency welding, the fixture 550 of fig. 60A-60B may be a dipole material and may be fused to the first and second panels 2 in the same high frequency welding step as the first and second panels are fused together. Alternatively, the fixture 550 may be fused to the panels 1 and 2 in a subsequent high frequency welding step.

Fig. 61A shows a portion of a headgear 300, i.e., a strap, having a securing device 550 fused thereto. Panel 1 and panel 2 of lace 300 overlap and overlap securing device 550 and are fused to provide a seamless transition between the lace and the securing device.

As shown in fig. 61B (which shows the arrangement of fig. 61A before the panels 1 and 2 are fused to the fixture 550), the fixture 550 has a recess 55 formed therein, which corresponds to the shape of the ends of the panels 1 and 2. The height of the securing device 550 also tapers toward the lace. These features may help provide a seamless transition between the lace and the securing device.

Fig. 62 shows another form of example of a fixture 550 that provides a slot instead of the hook feature shown in the fixtures of fig. 61A and 61B.

Although generally described as being connected by fusion, in other configurations, the securing device may be attached to the face plate of the headgear, for example, by other methods (such as by adhesive or by stitching).

While the securing device as a separate part may be attached to one or more panels of the headgear by fusing, such as shown and described with respect to fig. 61A-61B and 62, the securing device may additionally or alternatively be provided to the headgear by other methods.

One or more panels may be formed into a desired shape and then fused to form that portion of the panel into a solid plastic. For example, the ends of one or more panels may be curled to form the shape of the clip securing device 550 of fig. 61A, and then fused to solidify the one or more panels into that shape.

While one or more panels themselves may be fused to form the fixture, the fused portion may alternatively be used to form a substrate for overmolding that will form the desired fixture.

For example, the ends of one or more panels may be fused to form a portion that is sufficiently rigid to allow over-molding. In such a configuration, the ends of one or more panels may be formed into the shape of the final fixture or a portion of the shape, or may be fused into a flat configuration.

Once sufficient structural integrity is imparted by fusion, the ends of one or more panels may be inserted into a mold and over-molded with another material (e.g., a solid plastic material).

It may be desirable to ensure that the edges of the headgear or the edges of the respective panels are smooth and flexible to maximize patient comfort. In the case where the edge of the headgear is defined by the cut edge of the panel, the edge may require a treatment such as fusing to prevent it from unraveling unless the panel is made of a non-unravelable material. Such treatments may stiffen or stiffen the edges and make them less comfortable. Even if the edge is defined by a non-spreadable material, it may be desirable to further soften or smooth the edge.

One way of handling the edges of the or each panel is to fold around the other panel such that the periphery of the or each panel is no longer defined by the cut edge but by the continuous rolled surface of the panel.

Fig. 63 shows the first panel 1 with the second panel 2 already folded over one of the edges of the first panel. These panels may then be fused together, either around only a portion away from the folded edge or across the entire panel 1 and 2.

Fig. 64 shows another configuration of the first panel 1 and the second panel 2 folded around one edge thereof. In the configuration of fig. 64, the folded panel is not rigidly folded onto itself, but rather defines a void 530 at the edge. Such a void may be formed by using a sufficiently stiff panel for the second panel 2 so that it does not fold back on itself completely. The void may also be created by temporarily or permanently using an insert located at the edge and folding the second panel 2 around the insert.

Fig. 65 shows another configuration of the first panel 1 and the second panel 2 folded around its two lateral edges. In fig. 65, the second panel 2 also defines voids 535 and 536 at each folded edge.

Fig. 66 shows the configuration of fig. 65, but wherein voids 535 and 536 are filled with respective edge members 532 and 533. The edge members 532 and 533 may be provided at the edge of the first panel 1 when the second panel 2 is wrapped around the first panel 1, or in the case where a void is formed without an insert, the edge members 532 and 533 may be inserted into the voids 535 and 536 after the second panel 2 is wrapped around the first panel and they are fused together.

The edge member may be used to keep the void open. They may additionally or alternatively provide the edges with structures, such as shape memory. For example, when a wire is used as the edge member, it may be deformable but helps to maintain the edge in a set shape. Further examples of edge members may include beaded tubing or rope tubing.

Fig. 67 shows another second panel 2 wrapped around both edges of the first panel 1 but leaving one face of the first panel 1 left significantly exposed. The first panel and the second panel may then be fused at the location of arrow 817. Such a configuration may be desirable when the surface properties (e.g., UBL properties) of the first panel are to be utilized but the edges of the panel are to be softened or rounded.

Fig. 68A illustrates a headgear 10 according to one embodiment. Headgear 10 is attached to interface 600. The headgear has two tethers 301 and 302, and a rear portion 100. The headgear is formed from a plurality of overlapping and fused panels, and at least some edges of the headgear are defined by folded panels rather than cut edges.

Fig. 68B shows a section through line A-A of fig. 68A. The headgear strap 301 has a first panel 1 at cross section surrounded by a wider second panel 2 folded around the first panel. The folded edges each have a width that is about the same as the first panel 1, so that the assembly of the first and second panels together is about three times the width of the first panel 1.

Each folded edge defines a void 535 and 536 where the second panel 2 is folded back upon itself.

The use of inserts or tubes around which the panels are folded and welded may be used to define other features in addition to the edges of the headgear. For example, as shown in fig. 69A, a first panel 1 may be folded around bead 534, and then fused to itself adjacent bead 534 at the location of arrow 818. The free end of the first panel 1 may then be folded outwardly in the direction of arrow 819 to the configuration shown in FIG. 69B. In this configuration, the bead and the second panel wrapped therearound may define a slider along which an adjustable securing device (such as a hook or buckle) may slide.

As shown in fig. 69C, the assembly of fig. 69B may be further wrapped by a second panel 2 that provides a folded edge to the assembly rather than a cut edge.

Fusion may be deployed to form other types of adjustment mechanisms. For example, fig. 70A shows a panel or panel layup that has been fused to form an array of rigid plasticized buttons 551. The button 551 is a partial bump in a panel or panel overlay that can mate with another panel or fixture having a corresponding array of holes into which the button 551 can be coupled in the same manner as the snap-fit adjustment of a baseball cap.

Fig. 70B shows a cross section along the array of buttons 551 of fig. 70A, illustrating how one or more panels may be fused into a rigid bump.

Fig. 71 shows another form of adjustment feature in which the panel or panel layup has been fused to form an array of teeth 552. Teeth 552 may be used to provide a one-way adjustment mechanism having zipper properties.

The adjustment feature may be formed by fusion, which causes the material to melt and sag to form a button. They may also be formed using molds (such as molds 503 and 504 of fig. 9A and 9B) having protrusions and depressions corresponding to the desired shape of the adjustment features.

Additional material may be added between the panels of the headgear before fusing the panels together. These materials may be fusible or infusible materials. For example, inserts forming voids or pockets may be placed between panels, or beads or filaments forming edges may be placed between panels or within folds of one panel.

Fig. 72A shows an example embodiment of the headgear 10 attached to the interface 600.

Fig. 72B is a cross-section through the headgear 10 at line A-A of fig. 72A. At a cross-section, the headgear 10 has a first panel 1 that partially overlaps a second panel 2. The peripheral portions of the landing panels are fused to define a first fused region 41 and a second fused region 42. Filament 560 is located between the two overlapping panels and is located in the unfused region 51 between the two fused regions 41 and 42.

The filament 560 may provide additional structure to the headgear, such as shape memory in the case where the filament is a plastically deformable metal.

In other forms, such filaments 560 may be used to provide fit adjustment to the headgear, as will be described later.

The filament 560 may be interposed between the two panels before the two panels are fused in a discrete fusion process. In other forms, such as shown in fig. 72C, filaments 560 may be placed between the first panel 1 and the second panel 2 as part of a continuous fusion process.

Fig. 72D is another view of the fused first panel 1 and second panel 2, with filaments 560 disposed within a pocket defined by the area where the two panels are not fused to each other.

Fig. 73 is a partial view of headgear 10 having filaments 560 extending along top strap 200 in each of side straps 301 and 302. By securing the side strap end or top strap end of the wire 560 and then pulling on the other end, the fit of the headgear can be adjusted in the same manner as the pull cord.

As shown in fig. 73, the headgear 10 may include a securement device 550 through which the wire 560 passes to enable a secure adjustment of the tension on the wire 560.

In accordance with the present disclosure, headgear may include a rear portion and two or more straps for connection between the rear portion and the patient interface. Some or all of the straps of the headgear may be integrally formed with the headgear by being formed from one or more of the same lap panels as the rear portion of the headgear. In other configurations, one or more of the straps may be formed separately and then attached to the rear portion of the headgear. As previously described, fig. 11 illustrates a configuration in which separate tethers 200 and 301-304 are attached to the rear portion 100 to form the headgear 10.

When laid flat, one or more of the straps of the headgear may have a straight shape or a non-straight shape. The use of a strap having a straight shape when laid flat may increase the yield of the material or materials forming the strap.

The harness straps may be made of a single panel or multiple overlapping panels (like the rear portion). Alternatively, one or more of the straps of the headgear may have other material or materials, such as a foam and fabric laminate.

The strap, which is separately formed onto the rear portion of the headgear, may be attached to the rear portion by one or more different methods. In at least some configurations, one or more headgear straps may be fused to the rear portion. Fusion may be performed by welding, such as ultrasonic welding.

In other configurations, one or more tethers may additionally or alternatively be attached to the rear portion by other methods (such as gluing or stitching).

Some straps may be removably attached to the rear portion of the headgear rather than permanently attached. This may be advantageous, for example, to replace worn laces, or to change the type or size of laces used with a particular rear portion. One or more tethers may be removably attached to the rear portion by, for example, fasteners or clips or a hook and loop arrangement.

Where the attachment of the one or more tethers includes welding the tethers and the rear portion together, one side of the tethers may be welded to one or more panels of the rear portion. For example, in the configuration of fig. 11, the ties 200 and 301-304 have been placed on top of the overlapping first and second panels 1 and 2, respectively, and attached to them at only one side of each respective tie.

In other configurations, the lace may be at least partially sandwiched between two panels of the rear portion. Fig. 17A shows a rear portion 100 having non-fused regions 51-54 of the first panel 1 and the second panel 2 at each strap connection portion 120 such that a portion of the strap may be located between the first panel 1 and the second panel 2 and these components attached to one another, such as by welding. Fig. 17B then shows the respective ties that have been welded between the first panel 1 and the second panel 2 at each tie connection 120.

The strength of the fused connection between the strap and the rear portion may depend on the type of strap used and its material characteristics. For example, for certain types of fabric laminate foams that may be used as ties, the fused or more particularly welded connection between the laminate foam and the rear portion may be relatively reinforced with the laminate foam welded to the unfused portion of the rear portion.

More particularly, such a connection may be relatively reinforced where the laminated foam is welded to an unfused single panel rather than two or more overlapping panels.

Fig. 74 shows a headgear 10 having a rear portion 100 with a first panel 1 and a second panel 2. At the lateral extent of the rear portion, the first panel 1 extends beyond the second panel 2 to define lacing connection portions 120a and 120b of the first panel 1. The ties 200a/301 and 200b/303 have been overlapped on the tie connecting portions 120a and 120b and fused with the first panel 1.

As shown in fig. 74, the tethers 200a/301 and 200b/303 have been lapped over the patient facing side of the first panel 1, which is the opposite side of the second panel 2. In other configurations, tethers 200a/301 and 200b/303 may overlap on the non-patient-facing side of the first panel,

although the laces 200a/301 and 200b/303 are shown in fig. 74 as only partially overlapping the first panel 1 at the lace connection portions 120a and 120b, in other configurations, the non-overlapping portions of the first panel 1 at the lace connection portions 120a and 120b may be of sufficient size to allow the entire width of the laces to overlap thereon.

The strap attachment by fusing with the non-overlapping portion of the first panel 1 may be used at any strap or straps of the headgear, including any underside straps 302 and 304 of the headgear.

As previously mentioned, it may be desirable to limit the curve and width variation of the headgear strap in order to increase the yield of the material or materials forming the strap. Fig. 75 illustrates a configuration of the headgear 10 including separate tethers 200a, 200b, and 301-304.

Each of the straps 200a, 200b, and 301-304 of the headgear 10 of fig. 75, except for the strap end feature 330 of the second top strap 200b, has a constant width along their respective lengths.

While the second top strap 200b is shown as having a widened end with a slot for receiving the end of the first top strap 200a, it should be understood that other forms of attachment between the top straps (such as a snap or hook and loop fastening system) may be used to allow the second top strap 200b to have a constant width along its entire length.

As shown in fig. 75, each of the tethers 200a, 200b, 302, and 304 are also straight along their respective entire lengths. In addition to a single curve toward the attachment end of the rear portion 100, the upper tethers 301 and 303 are also straight. These curves may help to position the strap end in a desired proximity to the strap connection securement device of the patient interface in use.

However, in other configurations, the upper tethers 301 and 303 may be entirely straight along their length.

As shown in fig. 75, the ties 200a, 200b, and 301-304 have been placed atop the overlapping first and second panels and fused to the second panel 2 at the overlap region 21 of the rear portion 100. This provides a headgear 10 in which the tethers 200a, 200b, and 301-304 are located entirely on the non-patient facing side of the headgear.

Although shown in fig. 75 as being fused to only the second panel 2, and not to the non-overlapping portion 31 of the first panel 1, in some configurations, the tie may be fused to the overlapping portions of both the second panel 2 and the first panel 1.

The connection of the strap to the rear portion may be facilitated by inserting the strap end into a pocket of the rear portion of the headgear, as previously described, for example, with respect to fig. 48A-48D.

Fig. 76 shows a further embodiment of a headgear 10 having first and second top straps 200a, 200b and two pairs of upper and lower straps 301-302, 303-304. Each strap is connected to the rear portion 100 by inserting each strap end into a corresponding cutout 530 of the second panel 2.

In the case where the first panel 1 and the second panel 2 are fused together prior to the lacing connection, the fusion may leave unfused areas adjacent to each cut 530 to define a pocket 531 to accommodate the end of each lacing, as described with respect to fig. 48A-48D. Once inserted into the bag, the strap end and the first and second panels may then be fused together.

In case the first panel 1 and the second panel 2 are fused together at the same time as the tie is fused to them, no predefined pocket is needed between the first panel and the second panel, as the tie end can simply be inserted between the unfused first panel and the second panel.

As shown in FIG. 76, each of the tethers 200a, 200b, and 301-304 has a continuous width and is straight, except for the end of the side tethers 301-304 in the bag of the rear portion 100 and the tether connection securing means of the second tether 200 b. While the strap ends of the side straps 301-304 are shown as being angled with respect to the rest of each side strap, in other configurations, the strap ends connected to the headgear may not be angled with respect to the rest of each respective strap.

Fig. 77A shows another form of strap attached to the rear portion 100. As shown in FIG. 77A, the end portions of each of the tethers 200a, 200b, and 301-304 each pass through a corresponding slot 571-576 of the tether connecting portion of the rear portion 100. The lace ends are then folded back and attached to themselves. Such attachment may be in a releasable form, for example using a hook and loop fastening system.

Alternatively, as shown in fig. 77A and in further detail in fig. 77B, the lace may fuse to itself as shown by fused region 41 when inserted through the slot of the rear portion. When the lace is made of a fabric laminated foam, the fusion of the lace to itself may be preferred, which may be more effectively fused to another fabric laminated foam than to a separate textile (such as the first panel 1 or the second panel 2).

The slots 571-574 may be slots through the thickness of the rear portion 100 (e.g., through both the first panel 1 and the second panel 2).

In other forms, the slots 571-574 may pass through only one or more of the outer panels of the posterior portion, such as when it is desired to position the strap away from the patient contacting side of the posterior portion. In this configuration, the tie end will enter the pocket between the first panel 1 and the second panel 2 before extending through the corresponding slot and being folded back upon itself.

Although in fig. 77A slots are formed in one or more panels of the rear portion 100 to accommodate attachment of the laces, in other forms, some slots may be formed in the laces to allow other laces to be connected thereto.

For example, in fig. 78, the first top strap 200a and the second top strap 200b have slots 571 and 574 formed therein that receive the upper straps 301 and 303.

In the configuration of fig. 78, top ties 200a and 200b each overlap the rear portion to the most lateral extent of ear loop 320.

The slots 571 and 574 may be slots through only the top ties 200a and 200b, or may alternatively be slots through the top ties 200a or 200b and one or more panels of the rear portion 100 that they overlap.

The top strap portions 200a and 200b may be provided as part of two side straps, such as shown in fig. 74. In other forms, they may be provided as separate parts, such as shown in fig. 75. In still other forms, the top strap portions 200a and 200b may comprise one continuous piece, such as that shown and described previously with respect to fig. 34. The top strap comprising a continuous piece of material may enhance the ability to transfer loads between the ends of the top strap without having to rely entirely on the material of the rear portion 10 to transfer such loads. The use of a top strap comprising a continuous piece of material also eliminates the need for a separate top strap attachment fixture on the rear portion.

Fig. 79A shows a top strap 200 having two top strap ends 200a and 200b with a relatively thin central portion 200c connected therebetween. The top strap 200 has a straight shape. The shape of its non-curved form may allow one or more substrates forming it to have relatively improved yield.

Fig. 79B shows the top strap 200 of fig. 79A incorporated as part of the headgear 10, sandwiched between and fused to the first panel 1 and the second panel 2. Because the central portion 200c of the top strap 200 is relatively thin, the shape can be designed to follow the curve of the upper edge of the rear portion with minimal out-of-plane warping or twisting. With this configuration, the headgear may be provided with a continuous and curved top strap 200, and with increased material yield relative to the top strap 200 itself being formed into the desired curved shape.

The top strap 200 may be formed from a fabric laminated foam.

When the characteristics of the harness strap and the rear portion mean that the strap can be more firmly fused to its own material than the panel fused to the rear portion, the rear portion can have a portion of the same material as the strap added thereto to serve as the strap connecting portion.

Fig. 80 shows the headgear 10 wherein two wishbone-shaped strap material portions 575 and 576 have been overlapped to the second panel 2 at each lateral extent of the rear portion 100. For example, where the laces are made of fabric laminated foam, the lace material portions 575 and 576 may also be fabric laminated foam.

Both the laces 200a and 200b and the upper laces 301 and 303 have been placed atop and fused to the lace material portions 575 and 576.

The lace material portions 575 and 576 can be fused to the rear portion 100. Alternatively, the lace material portions 575 and 576 may be secured to the rear portion 100 by other methods (such as by adhesive or by stitching), particularly where a fused connection between the two materials may not provide sufficient strength.

The thinned wishbone-like configuration of lace material portions 575 and 576 can mean that they can be cut into a straight shape and then bent as they are applied to the posterior portion without causing undue distortion.

Although shown as a single piece at each side of the rear portion 100 in fig. 80, the strap material portions may be provided on the rear portion separately for one or more straps of the headgear.

Although the lacing material portion may be a fabric laminated foam, particularly when the lacing is a fabric laminated foam, the lacing material portion may alternatively be an adhesive, such as a hot melt adhesive.

Fig. 81 illustrates another example of a headgear 10 that includes strap material portions 575 and 576 to facilitate the attachment of straps 200a, 200b, and 301-304 to rear portion 100. As shown in fig. 81, the lace material portions 575 and 576 each extend continuously between three lace connection points on each lateral side of the rear portion.

In addition to being coupled to each other, the harness strap and rear portion of the headgear may be indirectly connected using an intermediate portion.

For example, as shown in fig. 82A, two tethers 200a and 301 may be inserted into an overmold 580, which is then attached to the rear portion 100 of the headgear. In fig. 82A, a mounting post 581 depends from the overmold 580. The mounting post 581 has a barbed or mushroom-like shape with a base 581b connected to the overmold 580 and a head with laterally extending wing portions 581 a. As shown in fig. 82A, the rear portion 100 has a cutout 582. The length of the cutout 582 is less than the length of the mounting post 581 between its two lateral wing portions 581 a. The rear portion 100 and the lacing assembly are connected by passing the cutout 582 through the mounting post 581 such that it is retained by the wing portion 581 a.

With this configuration, the harness assembly can be removably attached to the rear portion of the headgear. This may allow for changing the lace or lace groups or rear portions, such as changing worn items or providing different sizes, without requiring an entire replacement of the headgear.

In fig. 82B, a headgear 10 is shown having a corresponding overmold 580 overmolded onto straps 200a and 301 and 200B and 303 and connected to rear portion 100 by mounting posts 581.

The rear portion 100 is shown in fig. 82A and 82B as being connected to the harness assembly by a mounting post 581, which may also be overmolded to form a permanent connection rather than a removable connection.

As previously mentioned, it may be desirable to position the connection point of one or more straps of the headgear away from the patient-facing side of the rear portion. This may improve the continuity or smoothness of the patient facing side of the headgear and thus improve the comfort of the headgear.

However, it may also be desirable to connect both sides of the strap to the rear portion, rather than having a connection at only one side of the strap. Connecting both sides of the strap to the rear portion may provide increased joint strength. It may also reduce any twisting of the headgear at the junction.

Fig. 83A shows the strap attachment portion 120 of the rear portion 100. At the strap connection portion 120, the rear portion 100 includes an extension 58. The lace 300 is overlapped on the rear portion 100 on one side at the lace connection portion 120, and the extension 58 is folded over the lace 300 such that it overlaps with the rear portion 100 on both sides.

As shown in fig. 83B, the lace and the rear portion can be fused together at the lace connection 120 to attach the lace 300 with the rear portion 100.

While the various preferred embodiments utilize fusion to process non-overlapping areas or join multiple panels at overlapping areas, other methods of joining or processing panels may be utilized. For example, the panels may be joined by using an adhesive, or the various panels or panel portions may include stitched joints, particularly where such stitching does not adversely affect the volume of the headgear or particularly the thickness of the joints and the comfort of the patient when wearing the headgear. The panels may be further joined by using a securing device to hold the panels together.

The adhesive may be applied between the panels to be joined, or it may additionally or alternatively be applied to overlapping panels, such as by dipping or immersing the panels in the adhesive.

The term adhesive should be understood to encompass any one or more of the commonly available adhesive types or combinations. The adhesive may be, for example, an acrylic adhesive, an anaerobic adhesive, or a cyanoacrylate adhesive.

The binder may be, for example, an ester or ether based compound. More specifically, the binder may comprise nylon-polyamide, ester-polyurethane, polyester or polyolefin.

Especially in the case where the adhesive is provided in solid or semi-solid form (but also possible in the case where the adhesive is a liquid or gel), it may be necessary to activate the adhesive to initiate or accelerate the adhesive curing process to form a bond between the overlapping panels. For example, in the case of a solid or semi-solid adhesive, the adhesive may be activated by melting from its solid or semi-solid state. In other forms, the adhesive may be activated by a combination of two components of the adhesive, such as in the case of a two-component acrylic adhesive.

While the process of joining panels by adhesive forming a bond is referred to herein as curing of the adhesive, it should be understood that such curing may include forming a bond by: one or more chemical reactions within the adhesive or adhesive combination; presence of a specific environment (e.g., anaerobic environment) or contact with a specific type of material (e.g., alkaline material); drying; or applying one or more of pressure, heat, sound, or light; or any other common method of converting an adhesive into a bonded state.

In an example, the adhesive may be in the form of a solid or semi-solid hot melt adhesive. Heat may be applied to activate the adhesive by melting the adhesive, and the adhesive may be cured, such as by one of the curing processes described above, to form a joint between the respective overlapping panels.

The adhesive may be provided as a separate layer and assembled between the respective panels, which may then be activated to create the bond. In particular, where the adhesive is a liquid or gel adhesive, the adhesive may be applied to the area of one or both of the overlapping panels during assembly of the panels.

In the case where the adhesive is in the form of a hot melt adhesive, the adhesive may be provided as an adhesive tape. The tape or adhesive sheet may be capable of being cut to a desired planar shape to provide a desired bonding area of the panels.

Such a tape or hot melt adhesive sheet may also include a tacky or adhesive surface or surface coating such that the adhesive may provide at least some temporary holding of the panel to which the adhesive is assembled before the adhesive is activated.

While according to various embodiments, an adhesive may be used with the fusing of the panels to join and/or treat portions of the headgear, at least some preferred embodiments may exclude the use of an adhesive. The use of adhesives or any other additive joining method will essentially result in an increase in one or both of the weight or thickness of the joined panels.

For example, in the case of adhesive tape, it would be placed between the joined panels. While the adhesive may be melted, either entirely or partially, into one or both of the panels, the adhesive will increase the weight of the joined panels relative to the panels being directly fused to one another.

While generally shown as being entirely overlapped with the first layer, the second layer may only partially overlap with the first layer according to various embodiments.

While generally shown as being fused together over the entire portion of the overlap region, the overlap panels of the headgear may be fused together only or primarily around the boundaries of the overlap region. However, in this case the line of demarcation where the fusion is applied may still extend beyond the overlap region to any adjacent non-overlap region.

According to various aspects of the present disclosure, a headgear comprising a plurality of panels, each of the plurality of panels at least partially overlapping and fused together with another panel, may have a reduced weight relative to headgear formed by other methods.

Headgear according to the present disclosure may have a weight of less than about 30g, less than about 20g, or less than about 10 g.

In particular, various embodiments of headgear 10 according to the present disclosure may have a weight of about 17.5g to about 27.5g, and more particularly about 25 g.

While the foregoing description has referred to various general concepts of overlapping panels together and various features of particular embodiments of headgear formed from such overlapping panels, it is intended that any general concepts or features of particular aspects or embodiments may be combined with one another in any number of different ways to provide headgear or portions thereof within the scope of the present disclosure.

Claims

1. A headgear for a patient interface, the headgear comprising first and second overlapping panels defining an overlapping region in which the first and second panels overlap and overlap, respectively, and a non-overlapping region in which the first panel is not overlapped,

wherein at the overlap region adjacent surfaces of the respective overlapping panels are fused together.

2. The headgear of claim 1 wherein adjacent surfaces of the respective panels at the overlap region are directly fused to one another without any intervening material.

3. Headgear according to claim 1 or 2 wherein the overlap region comprises a fused portion and an unfused portion.

4. A headgear according to any one of claims 1 to 3 wherein the overlap region comprises a transition between a fused portion and an unfused portion, the transition defining a degree of fusion between the unfused portion and the fused portion, and the transition comprising a gradient of degree of fusion between the fused portion and the unfused portion.

5. The headgear of any one of claims 1-4, wherein the headgear comprises different stretch characteristics at each of:

a) The fused portion of the overlap region,

b) An unfused portion of the overlap region

c) A non-overlap region of the first panel.

6. The headgear of any one of claims 1-5, wherein adjacent surfaces of the first and second panels are fused together around the perimeter of the overlap region.

7. The headgear of any one of claims 1-6, wherein the second panel completely overlaps the first panel and adjacent surfaces of the first and second panels are fused together around the entire perimeter of the second panel.

8. The headgear of claim 7, wherein the perimeter of the overlap region comprises boundaries on both sides of the perimeter of the overlap region.

9. The headgear of claim 8 wherein the first and second panels are continuously fused together across the overlap region at two or more points around a perimeter of the overlap region or around the perimeter of the overlap region.

10. A headgear for a patient interface, the headgear having a central section comprising a first layer and a second layer and defining at least one stretch zone in which the first layer does not overlap the second layer and at least one relatively reduced stretch zone in which the first layer overlaps the second layer,

11. The headgear of claim 10 wherein the central section includes a reduced extensibility region at an upper portion thereof, and the reduced extensibility region is connected to lateral sections of the headgear on either side of the central section.

12. Headgear according to claim 10 or 11 wherein one or more layers of the headgear at one or more areas of reduced extensibility are welded.

13. The headgear of any one of claims 10 to 12, wherein the headgear further comprises: wherein the first layer overlaps the second layer, and wherein the headgear is unwelded at each of the one or more overlap extension regions.

14. The headgear of any one of claims 10-13, wherein the central section and one or more reduced extensibility regions of the lateral sections define a zone of the headgear, wherein a lateral extent of each lateral region defines one or more strap connection portions, and each of the one or more strap connection portions has an increased width relative to a portion of the zone at each respective lateral region.

15. The headgear of any one of claims 10-14, wherein the headgear has a lateral dimension along the zone and a width dimension perpendicular to the zone, and at one or both of these lateral sections, the second layer is about 60% to about 95% of the width of the first layer.

16. The headgear of any one of claims 10-15, wherein the headgear has a lateral dimension along the zone and a width dimension perpendicular to the zone, and the second layer is about 20% to about 70% of the width of the first layer at a lateral middle of the stretch zone.

17. The headgear of any one of claims 10 to 16, wherein any one of:

a) The first layer has a first extensibility value and the second layer has a second, smaller extensibility value, or

b) The first layer is a stretch layer and the second layer is a stretch-reducing layer.

18. A headgear for a patient interface, wherein the headgear has a strap portion and a plurality of strap connection portions and comprises a plurality of overlapping panels defining at least one overlapping region in which at least two panels of the plurality of panels overlap and overlap each other, respectively, and at least one non-overlapping region in which one or more of the plurality of panels does not overlap another of the plurality of panels,

wherein the headgear is welded at each of the at least one overlap region to join adjacent surfaces of the plurality of overlap panels together, an

b) One or more of the plurality of lacing connection portions has a second arrangement of welded adjacent panel surfaces and unwelded adjacent panel surfaces of one or more overlap areas within the or each respective one or more of the plurality of lacing connections, the second arrangement being different from the first arrangement.

19. The headgear of claim 18 wherein the first arrangement comprises a substantially fully welded adjacent panel surface and the second arrangement comprises a welded adjacent panel surface having one or more non-welded regions.

20. The headgear of claim 19, wherein the one or more non-welding regions are located within a line of demarcation with an edge of any overlap region within the one or more strap connection portions of the plurality of strap connection portions.

21. The headgear of any one of claims 18-20, wherein the headgear further comprises a plurality of straps corresponding to the plurality of strap connection portions, and wherein each strap of the plurality of straps is contained by one or more of the plurality of strap panels.