Classifications

• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. ventilators; Tracheal tubes
  • A61M16/06—Respiratory or anaesthetic masks
  • A61M16/0683—Holding devices therefor
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. ventilators; Tracheal tubes
  • A61M16/06—Respiratory or anaesthetic masks
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. ventilators; Tracheal tubes
  • A61M16/06—Respiratory or anaesthetic masks
  • A61M16/0605—Means for improving the adaptation of the mask to the patient
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M2205/00—General characteristics of the apparatus
  • A61M2205/02—General characteristics of the apparatus characterised by a particular materials
  • A61M2205/0216—Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M2205/00—General characteristics of the apparatus
  • A61M2205/58—Means for facilitating use, e.g. by people with impaired vision
  • A61M2205/582—Means for facilitating use, e.g. by people with impaired vision by tactile feedback
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M2207/00—Methods of manufacture, assembly or production
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
  • A61M2207/00—Methods of manufacture, assembly or production
  • A61M2207/10—Device therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
  • B29C66/729—Textile or other fibrous material made from plastics

Definitions

• the present invention relates to headgear for a patent interface.
• Respiratory interfaces or masks are used to provide respiratory gas or gases, such as air in CPAP therapy, including in for example VPAP and BiPAP systems, or NIV, or high flow rate therapy, for example.
• a respiratory interface may comprise a nasal, oral, or full face, i.e., both nasal and oral, interface.
• an interface may be an indirect interface which covers the nose, mouth, or both, or an indirect interface such as an interface comprising nasal nozzles or pillows or similar which enter into the nares of the wearer.
• Headgear for a respiratory interface may comprise at least two side straps which in use extend from a rear part of the headgear along the left and right sides of the patient's head to connect to the interface.
• Other configurations may include two sets of an upper and a lower side strap of each side.
• Headgear may also comprise a top strap such as a top strap or a forehead strap
• respiratory headgear may be in various other forms.
• headgear may comprise only a crown or forehead strap or an occipital loop, and a single strap on either side of the patient's head or face to the mask.
• the length of one or more of the headgear straps may be adjustable so that a patient can don the interface and headgear when the headgear strap or straps are loose and then tighten the straps when the interface and headgear are in position, to hold the mask and headgear securely in position thereafter until removal or doffing.
• Patients may use various types of respiratory interfaces or masks for the provision of different respiratory therapies.
• the interface must be retained in some way relative to either or both of the patient's mouth and nose. This is particularly the case where the respiratory therapy involves the provision of pressurised gases; the interface must be retained against the patient's face to provide at least some degree of a seal and prevent undesirable leakage of the respiratory therapy gases from the periphery of the interface.
• a headgear may be utilised to provide this function of retaining the interface on the patient's face.
• Respiratory interfaces or masks may be used in a variety of settings, including in hospital environments and in patients' homes.
• Various respiratory therapies may be provided either or both when a patient is awake or while they sleep.
• While a primary function of the headgear may be to retain the interface to the patient's face to counteract any pressure-generated forces and/or to create a seal with the patient's face, how the headgear transfers forces to the patient's head may significantly influence the patient's comfort and potentially also their compliance with the respiratory therapy. Load-carrying portions of the headgear may be liable to cause irritation or discomfort. This may particularly be the case where an interface and headgear are to be worn for an extended period of time, such as when sleeping.
• At least some parts of the headgear may be positioned between the patient's head and the bed. This may present further opportunities for discomfort for the patient, as a localised thickness of the headgear may cause increased pressures to be experienced by their head when the headgear is laid on.
• Different patients also may have significantly different anatomies. For example, they may have different circumferences of their heads, different face and skull shapes, and different tissue depths and sensitivities in different regions. This may be exemplified at the back of a patient's head, where some patients may have predominantly muscular necks or necks which taper significantly from their skulls, while other patients have more fat tissue or necks which do not taper as significantly from their skulls. These differences may result in different fits or comfort levels for a given headgear between different patients.
• a headgear may be adjusted in some ways to fit different patients, for example by shortening or lengthening one or more of the straps, such adjustments may not adequately compensate for the differences in anatomy between patients. Such adjustments may additionally or alternatively not provide for sufficient support or at least the sensation of support of the headgear on the patient's head. Ideally a headgear may be adjusted to comfortably suit the patient's anatomy, but also securely and snugly fit to the patient's head in the adjusted state.
• a headgear In addition to fit constraints for different patients, it may be desirable for a 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-away" function, where the headgear in a condition retaining the interface to the patient's face allows the user to pull the interface away from contact with their face. This may be to allow the patient to speak more clearly to someone, or to provide a brief respite from the therapy.
• a headgear itself may have particular and localised requirements for its structure and function. For example, to retain any given respiratory interface with some force, some regions of a headgear may experience greater loads than others. There may also be location specific needs for stiffness, flexibility, softness, or any number of other properties.
• Conventional headgear is commonly constructed from one or more joined sections of a laminate comprising external fabric layers which sandwich an internal foam layer, such as a natural or synthetic rubber foam. Portions of the headgear are cut from a sheet of the laminate, then connected with each other or other components to form the headgear.
• a laminate material which is used in the construction of headgear is Breathe-o-prene e .
• the headgear will have a thickness of at least the three or more layers that make up the laminate.
• the headgear will have the thickness of both joined sections. Even if efforts are made to reduce the thickness of the layers of each laminate, overlapping laminate sections can easily create undesirably thick regions and thus potential sources of discomfort for a wearer of the headgear. For example, where the laminates have three layers each, the resulting join will have a thickness of the total combined six layers.
• Foam materials may deteriorate over time, leading to a loss of their properties such as their recoverability of stretching.
• a headgear may be formed by a first panel and second panel which are lapped one over the other to define a lapped region, and which are fused together at the lapped region.
• One or both of the first panel and second panel may be partially not lapped by the other, and thus define one or more non-lapped regions of the headgear.
• the panels may be single-ply panels. Because the headgear may be formed from individual panels comprising single plies of one material or one composite of materials, rather than from joined laminates of multiple layers of different materials. At non-lapped regions the headgear comprises only the thickness of one single-ply panel, rather than at least three plies as in the case of the use of a three-layer laminate material such as Breathe- o-prene e . This may allow for a relative reduction in thickness.
• the panels may additionally or alternatively be multi-ply panels, for example a panel which is made up of multiple layers or plies of the same or different materials.
• the headgear of the present disclosure may also have a reduced thickness, ora thickness of only two panels compared to six panels in the case of a joint of two three-layer laminate materials such as Breathe-o-prene e .
• the panels may be cut to their respective desired shapes, then lapped with each other and joined together.
• Such a configuration may differ from conventional methods such as in the case of a laminate material such as Breathe-o-prene e where a headgear is built up by cutting already laminated panel sections, which are then joined together to form the headgear or parts of a conventional headgear.
• a headgear may be formed with non-lapped portions, where the headgear comprises a single panel which is not lapped by another panel.
• This configuration differs from conventional methods of constructing a headgear, such as by using cut sections of Breathe-o-prene e , where the headgear will always comprise 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.
• At least some parts of the headgear may additionally or alternatively be cut once they are lapped together and potentially once one or more lapped parts are joined together.
• the potential reduction in the number of panels and thickness at both lapped regions and non-lapped regions of the headgear of the present disclosure when compared to a conventional headgear made from joined laminate or multi-ply materials may provide either location-specific or overall reductions in the thickness of the headgear. Reduced thicknesses, whether in particular locations or across the whole headgear, may provide visual and/or physical perceptions to a patient of reduced bulk. Reduced thicknesses may also provide increased comfort for a patient wearing the headgear.
• any such reduction in the number of panels present at different points of the headgear and its thickness may provide corresponding decreases in the overall weight of the headgear.
• the panels may exclude any foam material.
• the headgear according to the disclosure may be fused, such as by welding.
• the headgear according to the disclosure may exclude a foam layer or layers, and the panels may be fused together across substantial parts or even all of their overlapped areas. For example, at least a relatively wider boundary around the perimeter of a lapped region may be fused than in a conventional laminated headgear.
• foam materials such as Breathe-o-prene e may allow for the use of different panel materials than are required for covering a foam layer. This may for example allow the use of lower cost, thinner, and lighter panel materials.
• the headgear of the disclosure may use panels made of lightweight and thin textiles. Accordingly, the overall thickness, and also the bulk and weight of a resulting headgear, may be reduced especially compared to conventional headgears constructed from laminated foams.
• a headgear according to the disclosure may utilise fusing to provide the desired properties of the headgear.
• Two lapped panels may be fused together about at least a periphery of the lapped region.
• Two lapped panels may be fused together about at least a border of the lapped region.
• Two lapped panels of a rear portion for a headgear may be fused together about an entire periphery of their lapped region, except for at one or more strap connection portions of the rear portion.
• one or more strap connection portions of a rear portion are left unfused in manufacture of the rear portion, they may be fused in a in a subsequent manufacture of a headgear.
• a strap may be interposed between the unfused first and second panels at the or each strap connection region, then the assembly fused together.
• At least the entire periphery of the lapped region of two first and second panels may be fused, where they are fused directly to each other at all but the strap connection portions, and at the strap connection portions are indirectly fused to each other by way of being fused to the interposed strap portion.
• Two lapped panels of a rear portion of a headgear may be fused to each other across their entire lapped region, but for at one or more strap connection portions, at which part of a strap is interposed between the lapped first and second panels, and the first and second panels are each fused to the strap.
• Two lapped panels a headgear may be fused to each other across their entire lapped region, but for at one or more pocket-forming regions of the lapped panels.
• An insert such as a strap end, may be provided within the pocket at the pocket-forming region before the lapped panels are fused together. Alternatively, an insert may be provided through an opening into the pocket after the lapped panels are fused together. Once an insert is provided within the pocket, the lapped panels and insert may be fused together, or remain unfused.
• Two lapped panels may be fused together from a first edge of the lapped region to an opposite edge of the lapped region.
• Two lapped panels may be fused together across the entire lapped region, but for minor regions within the interior of the lapped region.
• Two lapped panels may be fused together at a substantial entirety of the lapped region.
• Two lapped panels may be fused together across the entire lapped region.
• Two lapped panels may be fused together by full-surface fusing of the panels at the lapped region.
• Two lapped panels may be fused together such that a majority of the length along a line between two edges of the lapped region is fused.
• Two lapped panels may be fused together such that a majority of the length along any line between two edges of the lapped region is fused.
• the majority may be anywhere from a bare majority to a totality.
• references to an edge of a headgear or part of a headgear, such as of a lapped region, will be understood to include to any point along the perimeter of that part.
• panels which are joined by fusing may be fused together across large areas without the corresponding seam bulk or change to the surface finish that a large, stitched area would cause.
• Panels, and particularly textile panels, which are fused across large portions of the panels may provide firm yet flexible properties to the headgear.
• the fused areas may provide a visually clean and uniform surface to the panels.
• Selectively fusing and not fusing parts of the panels may allow for different material properties within regions of the same panel or panels. It may also provide differences in the surface features of regions made up of the same panel or panels.
• Fabric may be an example of a textile material.
• both panels may be a textile, such as a fabric.
• One or both of two lapped panels may be made of or include a polymer material.
• One or both of the two lapped panels may be made of or include a dipolar material.
• Two panels which are fused together may be formed into one integral composite panel at the lapped region, rather than two separate panels which are otherwise bonded together or affixed to each other.
• Fusing panels may present advantages over other additive methods of joining panels together, such as by stitching or the use of an adhesive.
• the weight and potentially also thickness of the joined panels may be relatively reduced.
• Fusing may additionally or alternatively be applied to panels at a non-lapped region of one or more lapped panels to alter the properties of the panel.
• a headgear according to the disclosure which has two lapped panels that define a lapped region may also have one or more non-lapped regions of one or both of the panels.
• a non-lapped of one panel may form a border around part or all of the other panel.
• a second panel may be provided wholly within the bounds of a first panel, so that a non-lapped border of the first panel extends about the second panel.
• a headgear according to the disclosure may have a non-lapped region about a periphery of part or all of the headgear.
• a headgear may have a non-lapped region or regions about both an upper and lower periphery of a rear portion of the headgear.
• the non-lapped region or regions may be formed by the same panel.
• the non-lapped region at the upper periphery of the rear portion of the headgear may be provided along a substantially straight perimeter of the lapped region.
• the non-lapped region at the upper periphery of the rear portion may be of a substantially continuous width.
• the non-lapped region at the lower periphery of the rear portion of the headgear may be provided along one or more curved portions of the lapped region.
• the non-lapped region at the lower periphery of the rear portion may be of a varying width.
• the non-lapped region at the lower periphery of the rear portion may have an edge with a radius of curvature less than that of an adjacent curved portion of the lapped region.
• the non-lapped region at the lower periphery of the rear portion may define one or more crescent shapes.
• a headgear according to the disclosure which has a first and second lapped panels which define a lapped region may be fused about an entire perimeter of the lapped region.
• the fusing about the entire perimeter of the lapped region may provide the first and second panels as a single unitary planar assembly with no free panel edges at the lapped region.
• a headgear according to the disclosure may have a rear portion that includes a first and second lapped panels and a non-lapped region of the first panel which defines at least part of a perimeter of the rear portion.
• the non-lapped region of the first panel comprises a border.
• the border is located, when the headgear is worn, at least at upper and lower edges of the rear portion.
• the border may vary in width away from the lapped region about the perimeter of the rear portion.
• the border provides an edge-softening effect.
• a headgear or rear portion for a headgear according to the disclosure which has a first and second lapped panels that are fused together at a lapped region of the panels may include two strap connection portions.
• two straps may be connected at the respective strap connection portions of the rear portion.
• the lapped region may define a contiguous fused zone of the first and second panels between the two strap connection portions. The contiguous fused zone of the first and second panels aids in load transfer across the headgear between the straps of the headgear.
• the lapped region may define more than one contiguous fused zone of the first and second panels between the two strap connection portions.
• the lapped region may define corresponding contiguous fused zones between each one of the straps and another one of the straps.
• the lapped region may define a single contiguous fused zones between each of the straps.
• a headgear according to the disclosure may have a first and second drapeable textile panels which are lapped against each other to define a lapped region within which the panels are fused together at a welded portion of the second panel.
• the welded portion may be the whole of the second panel at the lapped region, such that the first and second panels are fused together across the whole of the lapped region.
• the whole of the second panel may be lapped by 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 second panel may each have different stretch properties.
• the headgear may further comprise a strap portion configured to attach to a respiratory interface.
• the first and second panels may define a non-lapped region, and at the lapped region the first and second panels respectively overlap and underlap each other and at the non-lapped region the first panel is not lapped.
• first panel and second panel are fused together may define a fused zone
• the headgear may have reduced stretch at the fused zone compared to at the non- lapped region of the first panel.
• the headgear may have reduced stretch compared to at a non- fused portion of the second panel.
• a headgear according to the disclosure may include a first and second drapeable panels which are lapped against each other to define a lapped region and are fused together at the lapped region.
• the headgear may have a relatively reduced drape compared to one or more of a) the drape of the fist panel, b) the drape of the second panel, or c) the drape of a non-fused part of the lapped region.
• the first and second panels may be extensible, and the fused portion of the lapped region may have a relatively reduced extensibility.
• the first and second panels may be extensible, and the fused portion of the lapped region is relatively inextensible.
• the first and second panels may be extensible, and the fused portion of the lapped region is inextensible.
• the present disclosure provides a headgear comprising a plurality of panels which are lapped with each other, where the panels are joined together to define the headgear by fusion of the panels to each other.
• the panels are fused by welding.
• the panels are fused by radio frequency welding.
• the adjacent lapped surfaces of the panels are fused to each other, not just peripheral edges of the lapped parts.
• the present disclosure provides a headgear comprising a first panel and second panel which are lapped with each other, where the headgear is fused across a substantial part of the lapped part of the first panel and the second panel.
• the headgear is fused across a majority of the lapped part of the first panel and the second panel.
• the headgear is fused about an entire periphery of the lapped parts of the first panel and second panel.
• the headgear is also fused at a non-lapped part of either or both of the first panel and the second panel.
• the first and second panels are exclusively joined by fusing.
• the headgear is fused by radio frequency welding.
• the present disclosure provides a method of manufacture of a headgear for a patient interface, the method comprising the steps of: providing a first panel and a second panel which partially overlaps the first panel to define a lapped region, and applying a weld to the first panel and second panel, wherein the step of applying the weld comprises applying a weld to the lapped region and past an outer perimeter of the lapped region.
• the step of applying a weld further comprises applying a weld to a non-lapped region of the first panel and/or second panel, at which the panels are not lapped with each other.
• the present disclosure provides a headgear comprising a plurality of panels, where at least part of each panel is lapped against at least part of another panel and the lapped panels are fused together.
• a headgear comprising a first panel and a second panel which are lapped with each other to define a lapped region, and the first panel and second panel are fused together about a perimeter of the lapped region.
• the panels may be fused together about an entire perimeter of the lapped region.
• the panels may be fused together about an entire perimeter of the second panel.
• the present disclosure provides a headgear comprising two textile panels which are lapped against each other.
• the headgear consists of two textile panels and a plurality of strap fixtures.
• the two textile panels are partially fused together.
• the fusing is by welding.
• the present disclosure provides a headgear comprising two fabric panels which are lapped against each other.
• the headgear consists of two fabric panels and a plurality of strap fixtures.
• the two fabric panels are partially fused together.
• the fusing is by welding.
• the present disclosure provides a headgear comprising a first panel and second panel which are lapped with each other to define a lapped region and the first panel and second panel are fused together about a perimeter of the lapped region.
• the present disclosure provides a headgear comprising a first panel and second panel which are lapped with each other to define a lapped region and portions the lapped region away from its perimeter are bonded together, where the bond is of a material or materials of the first panel and second panel to each other.
• the panels are bonded together without any additive material such as a stitching or an adhesive.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other and a non-lapped region in which the first panel is not lapped, wherein, at the lapped region, adjacent surfaces of the respective lapped panels are fused together.
• the adjacent surfaces of the respective panels the lapped region are fused directly to each other without any interposed material.
• the lapped region comprises parts which are fused and parts which are non-fused.
• the lapped region comprises a transition zone between a part which is fused and a part which is non-fused, the transition zone defining a degree of fusion between that of the non-fused part and the fused part.
• the transition zone comprises a gradient of degrees of fusion between that of the fused part and the non-fused part.
• a majority of the lapped region is fused.
• the headgear comprises a third panel and the first panel, second panel, and third panel define the lapped region in which the first panel is respectively overlapped and underlapped by the second panel and third panel, and wherein adjacent surfaces of the first panel and second panel, and first panel and third panel, are each fused together.
• the second panel is fully lapped by the first panel.
• the first panel and second panel are both stretchable, and the first panel is more stretchable than the second panel.
• the second panel has one or more cut-outs to define a stretch zone of the first panel within the one or more cut-outs.
• the second panel is provided in two or more pieces to define one or more stretch zones of the first panel between the two or more pieces of the second panel.
• the headgear at the fused zone has one or more of a reduced stretchability, decreased thickness, or smoothed surface relative to the headgear at a non-fused zone.
• the headgear at the fused zone has reduced stretchability relative to each of the first panel and second panel.
• the lapped region comprises a plurality of discrete areas of the lapped panels.
• the non-lapped region comprises a plurality of discrete areas 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) a fused part of the lapped panels, b) a non-fused part of the lapped panels, and c) the non-lapped region of the first panel.
• the headgear at a fused part comprises one or more of a greater stiffness, a reduced extensibility, a lesser thickness, and a smoother surface texture than the headgear at a non-fused part.
• the non-lapped region of the first panel is a first non-lapped region
• the headgear further comprises a second non-lapped region at which the second panel is not lapped.
• the headgear comprises different stretch properties at each of: a fused part of the lapped region, a non-fused part of the lapped region, and the non-lapped region of the first panel.
• Adjacent surfaces of the first and second panels about a periphery of the lapped region are fused together.
• the panels are fused together by a heating of a material of one or both of the panels.
• the adjacent surfaces of the first and second panels are fused together about a whole periphery of the lapped region.
• the second panel is fully lapped by the first panel, such that an area of the second panel defines the lapped region.
• the second panel is fully lapped by the first panel, and the adjacent surfaces of the first and second panels are fused together about a whole periphery of the second panel.
• the periphery of the second panel is a border within a perimeter of the lapped region.
• Fusing is applied to the panels across a border both sides of the perimeter of the second panel.
• the periphery of the lapped region is a border within a perimeter of the lapped region.
• the periphery of the lapped region includes a border both sides of the perimeter of the lapped region.
• the border is greater than about 2 mm in width.
• the border is from about 2 mm to about 10 mm in width.
• the border extends beyond the lapped region by at least about 2 mm.
• the border extends beyond the lapped region by an amount at least equal to a predetermined panel placement tolerance during manufacturing.
• the heating is applied across the border, such that both the first and second panels at the lapped region of the border and the or each panel at the non-lapped region of the border are affected by the heating.
• the heating fuses together the first and second panels at the lapped region of the border.
• the heating comprises a melting of a material of one or both of the panels.
• the first and second panels at the lapped region are continuously fused together across the lapped region between two or more points about a or the perimeter of the lapped region.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other, and a non-lapped region in which the first panel is not lapped, wherein the lapped region and non-lapped region together comprise at least one first stretch zone and at least one relatively reduced second stretch zone, and wherein each at least one second stretch zone is defined by a fused portion of the lapped region and each at least one first stretch zone is defined by a non-fused portion of either or both of the lapped region and the non-lapped region.
• a fused portion of the lapped region is less stretchable than a non-fused portion of the lapped region.
• a fused portion of the non-lapped region is less stretchable than a non-fused portion of the non-lapped region.
• the headgear is more stretchable than the headgear at a second stretch zone.
• the headgear is substantially non-stretch.
• the first layer is a stretch layer
• the second layer is a relatively lower stretch layer
• Each of the lapped region and non-lapped region comprise each of a stretch zone and a non-stretch zone.
• the present disclosure provides 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 region where the first layer is not lapped by the second layer and at least one reduced stretch region where the first layer is lapped by the second layer, wherein the stretch region is located between laterally spaced strap connection portions of the central section.
• the central section comprises a reduced stretch region at an upper portion thereof, and the reduced stretch region connects to lateral sections of the headgear either side of the central section.
• One or more reduced stretch regions of the central section and lateral sections define a band of the headgear.
• the reduced stretch region extends beyond the bounds of where the first layer is lapped by the second layer.
• the layer or layers of the headgear at the reduced stretch region or regions are welded.
• the headgear further comprises one or more lapped stretch regions where the first layer is lapped by the second layer, and wherein at each one or more lapped stretch region the headgear is unwelded.
• a lateral extent of each lateral region defines one or more strap connection portions.
• Each of the one or more strap connection portions have an increased width relative to a part of the band at each respective lateral region.
• the one or more strap connection portions each include at least one of the one or more lapped reduced stretch regions.
• the headgear has a lateral dimension along the band and a width dimension perpendicular thereto, and at one or both of the lateral sections the second layer is about 60% to about 95% of the width of the first layer.
• the second layer is about 70% to about 80% of the width of the first layer.
• the second layer is about 80% to about 90% of the width of the first layer.
• the headgear has a lateral dimension along the band and a width dimension perpendicular thereto, and at a lateral middle of the stretch region the second layer is about 20% to about 70% of the width of the first layer.
• the second layer is about 40% to about 60% of the width of the first layer.
• One or more of the one or more strap connection portions laterally tapers away from the strap.
• One or more of the one or more strap connection portions have a triangular shape.
• the one or more strap connection portions include a strap, and the strap connection portion and strap are comprised by a stretch panel and/ora relatively reduced stretch panel.
• the stretch region of the central section is located between the band and two strap connection portions.
• the lapped region is continuous.
• the non-lapped region is continuous.
• the first layer is of a first stretch value and the second material is of a second lesser stretch value.
• the first layer is a stretch layer and the second layer is a relatively reduced stretch layer.
• the first layer is a stretch layer and the second layer is a non-stretch layer.
• the present disclosure provides a headgear for a patient interface, wherein the headgear has a band portion and a plurality of strap connection portions and comprises a plurality of lapped panels which define at least one lapped region in which at least two of the plurality of panels respectively overlap and underlap each other and at least one non-lapped region in which one or more of the plurality of panels is not lapped by another of the plurality of panels, wherein the headgear is welded at each at least one lapped region to fused ether adjacent surfaces of the lapped panels, and a) the band portion has a first arrangement of welded and non-welded adjacent panel surfaces of one or more lapped regions within the band, and b) one or more of the plurality of strap connection portions has a second arrangement, different from the first arrangement of welded and non-welded adjacent panel surfaces of one or more lapped regions within the or each respective one or more of the plurality of strap connections.
• the first arrangement comprises substantially entirely welded adjacent panel surfaces.
• adjacent panels surfaces may be welded to each other except for parts minor internal regions of the headgear.
• Adjacent panel surfaces may be welded to each other except for parts which define a desired surface texture.
• the second arrangement comprises welded adjacent panel surfaces with one or more non-welded zones.
• the one or more non-welded zones are located within a boundary from an edge of any lapped region within the one or more of the plurality of strap connection portions.
• the boundary is at least 2 mm.
• the boundary is from about 2 mm to about 10 mm.
• the one or more non-welded zones further comprise one or more spot welds to limit separation of lapped panels within the or each of the one or more non-welded zones.
• Welded regions of the headgear extend beyond a perimeter of each at least one lapped region.
• Welded regions of the headgear include a border zone of any non-lapped region adjacent to a lapped region.
• the border is from about 2 mm to about 10 mm in width.
• the border extends beyond the lapped region by at least about 2 mm.
• the border extends beyond the lapped region by an amount at least equal to a predetermined panel placement tolerance during manufacturing.
• a welded part of a lapped region comprises different material properties from a non- welded part of the same lapped region.
• a welded part of a non-lapped region comprises different material properties from a non-welded part of the same non-lapped region.
• the headgear further comprises a plurality of straps corresponding to the plurality of strap connection portions, and each of the plurality of straps are comprised by one or more of the plurality of lapped panels.
• the headgear further comprises a plurality of straps, one for connection to each of the plurality of strap connection portions.
• the plurality of panels comprise a first panel and a second panel which is fully lapped by the first panel, the first panel and second panel defining a lapped region and at least one non-lapped region of the first panel, and wherein the lapped region comprises each of the band and at least two of the plurality of strap connection portions.
• Each of the plurality of strap connection portions depend from the band.
• At least one pair of the strap connection portions expand laterally from where a strap is to be connected towards the band.
• the band further comprises one or a pair of top straps.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a first stretch material and a second stretch material in respective panels which are at least partially lapped with each other, wherein the lapped panels of the first stretch material and second stretch material are joined together at a joined region such that they have low stretch.
• the first stretch material is more stretchable than the second stretch material.
• the headgear is less stretchable than that of either the first stretch material alone or the second stretch material alone.
• the headgear is less stretchable than the lapped first stretch material and second stretch material at a non-joined region.
• the low stretch where the lapped panels are joined together is a relatively lower stretch than at a lapped panels are not joined together.
• the headgear is of a reduced stretch relative to a non-joined region.
• the headgear is substantially non-stretch.
• the lapped panels of the first stretch material and second stretch material are joined together at the joined region by fusion of the panels together.
• the lapped panels of the first stretch material and second stretch material are joined together at the joined region by fusion by melting of one of the materials into the other of the materials.
• the present disclosure provides a method of manufacture of a headgear for a patient interface, the method comprising the steps of: providing a first panel and a second panel, the panels defining a lapped region in which the first and second panels respectively overlap and underlap each other and a non- lapped region in which the first panel is not lapped, and melting one or both of the panels at the lapped region so as to fuse the panels together and define a fused zone of the lapped region.
• the method further comprises the step of melting the first panel at the non-lapped region to define a fused zone of the non-lapped region.
• the first panel is melted to define a fused zone about a perimeter of the lapped region.
• the step of melting one or both of the panel sat the lapped region and the step of melting the first panel at the non-lapped region are provided as a single operation.
• the step or steps of melting comprise the application of a heat and pressure to the first and/or second panels.
• the first panel has a first melting point
• the second panel has a second melting point
• the step or steps of melting comprise raising the temperature of at least part of the first panel and second panel above both of the first melting point and the second melting point.
• the first melting point is higher than the second melting point.
• the step or steps of melting comprise raising the temperature of at least part of the first panel and second panel to temperature above the second melting point but below the first melting point.
• the step or steps of melting comprise the application of a heat and pressure to both of the first panel and the second panel, but only the second panel is melted.
• the step or steps of melting comprise a welding.
• the first panel and second panel are provided between a first and second dies.
• the method further comprises the step of moving the first and second dies towards each other.
• the step of moving the first and second dies towards each other is comprised by the step or steps of melting.
• the first die comprises a first relatively raised level and second relatively recessed level, wherein the first level defines the fused zone or zones, and the second level defines an unfused zone at which the panel or panels of the headgear are not melted.
• the first die comprises a substantially immediate transition between the first level and the second level.
• the first die comprises a graded transition between the first level and the second level.
• the graded transition of the first die defines a transition zone between the fused zone and the unfused zone of the headgear.
• the level of the graded transition of the first die varies linearly between the first level and the second level.
• the level of the graded transition of the first mould palate follows an s-curve shape.
• the first level and second level define in relief an indicia, such that when melted the headgear comprises one or more fused zones and unfused zones which represent the indicia.
• the method further comprises 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 comprise a cutting element, and the step of cutting is combined with the step of moving the first and second dies towards each other.
• the step of melting one or both of the panels at the lapped region occurs after a bringing together of the two dies with the first panel and second panel therebetween.
• the step of melting the first panel at the non-lapped region occurs after a bringing together of the two dies with the first panel and second panel therebetween.
• the first panel is more stretchable than the second panel.
• One of the first panel and the second panel has a higher melting point than the other of the first panel and second panel.
• the disclosure provides a rear portion of a headgear, the rear portion comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other and a non-lapped region in which the first panel is not lapped, wherein, at the lapped region, adjacent surfaces of the respective lapped panels are fused together.
• the disclosure provides for a headgear comprising the rear portion and a pair of straps, each strap sandwiched between the first panel and second panel at the lateral ends of the lapped region.
• the lapped first panel, second panel, and strap are fused together at each lateral end of the lapped region.
• the present disclosure provides a headgear comprising a plurality of panels, where at least part of each panel is lapped against at least part of another panel they are joined together to provide a thin and seamless or substantially seamless headgear.
• each panel is joined together by a fusing of one or both panels into the other or each other of the panels.
• the present disclosure provides a headgear comprising a plurality of panels, where at least part of each panel is lapped against at least part of another panel they are fused together to provide a lightweight headgear.
• the present disclosure provides a headgear comprising a plurality of panels, where at least part of each panel is lapped against at least part of another panel they are fused together, wherein the panels are configured such that the headgear retains at least some of its in-use shape when in an at-rest state.
• At least one of the plurality of panels comprises a different material to that of another panel of the plurality of panels. At least one of the panels at a lapped region comprises a different material to that of another panel at a lapped region.
• the plurality of panels comprise a first panel and a second panel, and the first panel comprises a different material to that of the second panel.
• the plurality of panels further comprise a third panel, and the second and third panels comprise the same material, which is a different material to that of the first panel.
• Different materials comprise one or more of a different texture, softness, stretch properties including one or more of in-plane stiffness, out-of-plane flexibility, and recoverability, density, thickness, colour, frictional coefficient in relation to a reference material, breathability, or degree of transparency or sheer.
• Different materials comprise one or more of a directionally different: texture, softness, stretch property including one or more of in-plane stiffness, out-of-plane flexibility, and recoverability, or frictional coefficient in relation to a reference material.
• the two opposed major faces of at least one panel of the plurality of panels comprises one or more of a different texture, frictional coefficient, or colour of the opposed major faces of the panel.
• Exposed portions of major faces of the plurality of panels define an internal surface and an external surface of the headgear relative to the head of a patient in use, and wherein at least some of the plurality of panels each define part of the internal surface and/or the external surface of the headgear.
• the at least some of the plurality of panels comprise one or more of a different texture, softness, colour, or frictional coefficient in relation to a reference material.
• the at least some of the panels defining part of the internal surface of the headgear comprise a greater surface softness than that of at least some of the panels defining part of the external surface of the headgear.
• an exposed portion of a panel either defines part of one or the other of the internal surface and external surface.
• the plurality of panels comprise a panel of first stretch material and a panel of second stretch material, where the stretchability of the first stretch material and the second stretch material are different.
• the first stretch material is more stretchable than the second stretch material.
• the plurality of panels comprise at least one elasticated textile panel and at least one non-elasticated textile panel.
• the plurality of panels comprise: a rear portion for location at the rear of the head of a patient, a top strap, and at least two side straps for attachment to the patient interface.
• the rear portion transfers loads between the at least two side straps, and the rear portion comprises at least one panel of a first material which laps a portion of a side strap panel of each of the at least two side straps.
• the rear portion comprises a plurality of panels of the first material, and each of the at least two side straps are lapped on respective sides by panels of the first material.
• An extent of the rear portion to be located lowest on the rear of the head of a user comprises a lower panel of a second material.
• the second material is non-unravelable material.
• the lower panel is lapped to or between one or more of the plurality of panels of the first material.
• 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 a stretch panel and the plurality of panels of the first material are non-stretch panels.
• the lower panel of the second material is elasticised, and the plurality of panels of the first material are non-elasticised.
• 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
• first material is a substantially inelastic material
• a portion of the lower panel is in a non-lapped region of the headgear, and the portion of the lower panel is substantially crescent-shaped.
• At least a portion of the lower panel within a non-lapped region of the headgear is substantially crescent-shaped, having a concave edge and a convex edge, and wherein the concave edge forms at least a portion of a lower peripheral edge of the rear portion.
• the rear portion comprises an upper edge panel, the upper edge panel forming at least a portion of an upper peripheral edge of the rear portion, the upper edge panel comprising a material that is thinner and/or softer than that of a panel to which it is lapped.
• the upper edge panel is lapped to another panel at the rear portion so as to define an internal surface, relative to the head of a patient in use, of the headgear at an upper region of the rear portion.
• the upper edge panel is provided within both a lapped region and a non-lapped region, and wherein the non-lapped region forms at least part of an upper peripheral edge of the rear portion.
• the upper edge panel at the non-lapped region is configured, in use and towards the upper peripheral edge of the rear portion, to roll away from the head of the patient.
• the upper edge panel at the non-lapped region extends away from an adjacent lapped region a distance of about 5 times to about 20 times the thickness of the upper edge panel.
• the top strap defines an internal surface oriented towards the head of the patient in use and an external surface oriented away from the head of the patient in use, and wherein the internal surface has a greater softness than that of the external surface.
• the top strap depends from the rear portion.
• the top strap depends from the rear portion and at least one side strap of each lateral side of the rear portion and/or top strap.
• the top strap has a width greater than that of the at least two side straps.
• the top strap is of a different colour to that of the at least two side straps.
• the top strap comprises a pair of top strap portions which are adjustably fixable to each other to provide a variable-length top strap, each top strap portion comprising an internal top strap portion panel and an external top strap portion panel adhesively bonded to each other.
• the internal top strap portion panels have a greater softness than that of the external top strap portion panels.
• the internal and external top strap portion panels respectively overlap and underlap the panel or panels of the rear portion and/or side straps to which they are lapped.
• the top strap is relatively stiffer and/or denser than the rear portion.
• the top strap comprises one or more panels of a material having a greater stiffness and/or greater density than that of one or more panels comprising the rear portion.
• the at least two side straps comprise two lateral sets of an upper and a lower side strap, each set of side straps for connection to corresponding sides of the patient interface.
• the two upper side straps comprise a unitary panel which extends across the rear portion of the headgear.
• the unitary panel is provided within a lapped region across at least part of the rear portion of the headgear and within a pair of distal non-lapped regions.
• An upper and lower side strap comprise a unitary panel, the unitary panel configured to extend around a rear of the ear of a patient.
• a lapped region of the upper side straps is respectively overlapped and underlapped by panels of the top strap.
• the lower side straps are overlapped and underlapped by a plurality of panels of the rear portion.
• An ear loop for passing behind the ear of a patient defines a lateral peripheral edge of the rear portion between each lateral set of upper and lower side straps.
• each ear loop comprises a pair of straight-line portions.
• the pair of straight-line portions form a V-shape, the tip of each V directed towards the other and into the rear portion of the headgear.
• the two upper side straps comprise two respective panels, each provided within a lapping region at the rear portion of the headgear and within distal non-lapping regions.
• Each of the two respective panels of the two upper side straps are overlapped and underlapped by panels of the rear portion of the headgear.
• Terminal portions of either or both of the upper and lower side straps include gripping tabs comprising a first and second tab panels, the tab panels respectively overlapping and underlapping the terminal portion at a first tab region and lapping each other at a more distal second tab region.
• the first and second tab panels are of a material that is one or more of thinner, softer, of a different colour, or has a lower coefficient of friction with respect to a reference material than that of the material of the respective straps of the sets of upper and lower side straps.
• the first and second tab panels are of a plastics material that is one or more of thinner, harder, stiffen of a different colour, or has a lower coefficient of friction with respect to a reference material than that of the material of the respective straps of the sets of upper and lower side straps.
• the headgear at the second more distal tab region is of greater stiffness than the headgear at the first tab region.
• the second more distal tab region is thinner than one or more of the upper and lower side straps at a non-lapped region.
• the gripping tabs further comprise at one external surface a first half of a hook and loop fastener.
• the side straps are configured such that the strap surface which corresponds to the first half of the hook and loop fastener, when the strap is folded back on itself, comprises a second half of the hook and loop fastener.
• the at least two side straps comprise a left and right side straps, each side strap for connection to a corresponding side of the patient interface.
• Each side strap of the set of side straps is configured to fold back onto and attach to itself to define a connection loop by which the patient interface may be retained.
• Each side strap of the set of side straps comprises a series of visual features along at least one surface of the side strap, the visual features for indicating adjustment points to the patient when folding a side strap back onto itself.
• the visual features are regularly spaced along the surface of each side strap.
• Each side strap of the set of side straps comprises a series of tactile features along at least one surface of the side strap, the tactile features for providing a tactile feedback to a patient of different adjustment conditions of the respective strap.
• the series of tactile features provide for indexing of the adjustment of each respective side strap.
• An interaction of the tactile features with the patent interface provides the tactile feedback to the patient.
• Each side strap comprises a strap panel, the strap panel lapped on at least one major face with a tactile feedback panel, wherein the tactile feedback panel is one or more of thinner, harder, and stiffer than the strap panel which it laps and wherein the tactile feedback panel and the strap panel are fused together.
• the tactile feedback panel comprises the tactile features, the tactile features provided by a series of voids through the tactile feedback panel.
• the series of voids present the tactile feedback panel as having a series of ridges relative to the strap panel to which it is lapped.
• the tactile feedback panel is harder and/or stiffer than the strap panel, and the series of ridges are for mechanically engaging with a buckle of the patent interface.
• Each respective lateral extent of the top strap and rear portion non-lappingly interface with each other and an end of a respective one of the side straps.
• Each respective lateral extent of the top strap and rear portion and end of the respective side strap interface with each other in an edge-to-edge configuration.
• Each respective lateral extent of the top strap and rear portion and end of the respective side strap are lapped on at least one set of major faces by a joint panel.
• At least one major face of one or more of the top strap, rear portion, and side straps is lapped along at least a portion towards their peripheries with a stiffening panel.
• the stiffening panel comprises a stretch material which is less stretchable than the respective one or more of the top strap, rear portion, and side straps.
• the stiffening panel comprises a relatively reduced stretch material.
• the stiffening panel comprises a low stretch material.
• the stiffening panel comprises a non-stretch material.
• the stiffening panel comprises a substantially inextensible material.
• the stiffening panel comprises a non-elasticated material.
• the top strap comprises a single unitary strap.
• the rear portion comprises a single unitary strap.
• the top strap and rear portion comprise a closed loop.
• the set of side straps depend from intersections of the top strap and rear portion.
• intersections of the top strap and the rear portion are, in use, located above the ear of a patient.
• One or more of the set of side straps, the rear portion, and the top strap comprise at least in part a first stretch panel which is overlapped and underlapped by a pair of second stretch panels, where the first stretch panel is more stretchable than the second stretch panels.
• One or more of the set of side straps, the rear portion, and the top strap comprise at least in part a relatively elastic panel which is overlapped and underlapped by respective relatively inelastic panels.
• An entirety of one or both of the top strap and rear portion comprise a first stretch panel which is overlapped and underlapped by a pair of second stretch panels, where the first stretch panel is more stretchable than the second stretch panels.
• top strap and rear portion comprise a relatively elastic panel which is overlapped and underlapped by respective relatively inelastic panels.
• the rear portion and top strap form a closed loop, and the rear portion and top strap together comprise a relatively greater stretch panel and a relatively lesser stretch panel.
• the rear portion and top strap comprise two relatively lesser stretch panels, the two relatively lesser stretch panels each at a respective first end are lapped with a relatively greater stretch panel and at the other ends are lapped with each other.
• the rear portion and crown portion comprise a single relatively lesser stretch panel, the single relatively lesser stretch panel lapped at two lateral ends to one or more relatively greater stretch panels.
• Terminal portions of either or both of the upper and lower side straps include gripping tabs comprising a first and second tab panels, the tab panels respectively overlapping and underlapping the terminal portion at a first tab region and lapping each other at a more distal second tab region.
• the first and second tab panels are of a material that is one or more of thinner, softer, of a different colour, or has a lower coefficient of friction than that of the material of the respective straps of the sets of upper and lower side straps.
• the headgear at the second more distal tab region is of greater stiffness than the headgear at the first tab region.
• the gripping tabs further comprise at one external surface a first half of a hook and loop fastener.
• the side straps are configured such that the strap surface which corresponds to the first half of the hook and loop fastener, when the strap is folded back on itself, comprises a second half of the hook and loop fastener.
• One or more of the plurality of panels comprise an unravelable material.
• At least part of an edge of the headgear is treated by a conditioner.
• An edge portion which is treated by the conditioner comprises increased fray resistance relative to a non-adhesive lapped edge portion of the same material.
• At least part of an edge of the headgear is rolled back onto itself.
• An adhesive is provided between the rolled-back portion and the portion onto which it is rolled back.
• At least part of an edge of the headgear comprises an edge softening panel, a portion of which is lapped to a more interior panel, and wherein the edge panel comprises a material that is thinner and/or softer than that of the more interior panel to which it is lapped.
• the edge panel is lapped to the more interior panel such that the edge panel defines an internal surface, relative to the head of a patient in use, of the headgear.
• the edge panel is configured, in use and towards its outer end, to roll away from the head of the patient.
• the edge panel at the non-lapped region extends away from an adjacent lapped region a distance of about 5 times to about 20 times the thickness of the more interior panel to which it is lapped.
• the headgear has a weight of less than about 30 g.
• the headgear has a weight of less than about 20 g.
• the headgear has a weight of less than about 10 g.
• the headgear has a weight of about 15 g to about 30 g.
• the headgear has a weight of about 17.5 to about 27.5 g.
• the headgear has a weight of about 25 g.
• One or more of the plurality of panels comprise planar panels.
• the disclosure provides a headgear comprising a first panel which includes a selectively fused zone, wherein in the selectively fused zone the first panel is contiguously fused along a first direction and at least in parts discontiguously fused along a second direction, the second direction being a different direction to the first direction.
• At least some fused parts of the first panel are non-contiguous with each other.
• the fused zone is non contiguous.
• the headgear comprises a second panel at least partially lapped with the first panel, and the selectively fused zone includes at least part of the lapped panels.
• 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 selectively fused zone is provided to one or more elongate portions of the headgear, and the first direction is taken transverse to the length of each elongate portion and the second direction is taken along the length of each elongate portion.
• the elongate portions comprise a plurality of straps.
• the elongate portions comprise a rear loop.
• the selectively fused zone is provided at a bifurcated portion of the headgear and the second direction is taken across the bifurcation and the first direction is taken along respective sides of the bifurcation.
• the first direction is a direction of load transfer between two parts of the headgear, and the second direction is substantially perpendicular to the direction of load transfer.
• the headgear comprises a first selectively fused zone between lateral sides of a rear portion of the headgear and a second and third selectively fused zones each between respective lower strap connection portions of the rear portion and the first selectively fused zone.
• the selectively fused zone is configured such that when coupled to an interface the headgear defines a contiguous loop of fused material from a first side of the interface around the patient's head and to a second side of the interface.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other and a non-lapped region in which the first panel is not lapped, wherein the panels are fused together at the lapped region, and wherein a width of the non-lapped region varies.
• the non-lapped region is relatively more stretchable than the lapped region.
• the first panel is a stretch panel and the second panel is a non-stretch or relatively reduced stretch panel.
• the headgear comprises one or more stretch zones, and at the or each stretch zone the width of the non-lapped region is locally increased.
• the non-lapped region has a locally increased width at ear loops of the headgear which are to be located, in use, around the ears of the patient.
• the greatest width of the non-lapped region at the ear loops of the headgear is at a region to be located, in use, above and behind the ears of the patient.
• the ratio of total width of the non-lapped region or regions to the lapped region is from about 1 :1 to about 3:1.
• the non-lapped region at an upper side of a rear portion of the headgear has a substantially constant width, and the width of the non-lapped region at a lower side of the rear portion of the headgear varies.
• the disclosure provides a headgear for a patient interface, the headgear comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other, wherein a filament is provided between the first and second panels at the lapped region and the panels are fused together either side of the filament.
• the filament is able to be drawn between panels.
• the filament extends around a loop of the headgear between two patient interface connecting ends of the headgear, and the filament is drawable between the panels in order adjust a fit of the headgear.
• the disclosure provides a headgear for a patient interface, the headgear having three stiffening structures at each side of the headgear: a) a first stiffening structure to provide stiffness between a rear portion and a top strap of the headgear, b) a second stiffening structure to provide stiffness between the top strap and an upper side strap of the headgear, and c) a third stiffening structure to provide stiffness between the rear portion and a lower sides trap of the headgear, wherein the three stiffening structures are formed by a fusing of the headgear at each of the respective locations.
• the headgear comprises a first panel and the fusing of the headgear comprises a fusing of the first panel.
• the headgear further comprises a second panel which is at least partially lapped with the first panel, and the fusing comprises at least in part a fusing of the lapped first panel and second panel.
• the panel or panels comprise a textile including a polymer material, and the panel or panels when fused form a solid plastic.
• the three stiffening structures are formed by a fusing of the panel or panels, exclusive of any additional component provided to the panel or panels.
• the three stiffening structures are contiguous with each other.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a rear portion that has a first and second lapped panels, and at least two straps, wherein each of the at least two straps are fused to only the first panel of the rear portion.
• the second panel does not overlap any of the at least two straps.
• the present disclosure provides a headgear for a patient interface, the headgear comprising a rear portion that has a first and second lapped panels and a plurality of straps lapped and fused to the rear portion, wherein the parts of each of the straps that are not lapped to the rear portion are straight.
• each of the straps that are not lapped and to the rear portion are of constant width.
• Both the parts of each strap that are lapped and are not lapped to the rear portion are straight and/or of constant width.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, at least one slot cut in the second panel, and at least one strap, each strap having a strap end inserted through a respective slot so as to be located between the lapped first panel and second panel, wherein each at least one strap and the rear portion are joined by a fusing of the first and second panels and each at least one strap end.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, at least one slot cut in the second panel, and at least one strap, each strap having a strap end inserted through a respective slot and folded back onto itself.
• Each at least one strap is joined to the rear portion by being fused to itself at the folded back portion.
• Each at least one strap is joined to the rear portion by a releasable connection of the strap to itself at the folded back portion.
• the at least one slot is cut through both the first panel and second panel.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, and a top strap with a thinned central region that is sandwiched between the first and second lapped panels of the rear portion, wherein the rear portion and top strap are joined together by fusing.
• the top strap before incorporation into the headgear has a straight shape.
• the top strap when sandwiched between the first and second panels has a curved shape.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, a plurality of straps, and a strap material layer overlaid on the lapped first and second panels, wherein the strap material layer comprises the same material as each of the plurality of straps, and the plurality of strap are each lapped against the strap material layer and fused thereto.
• the headgear comprises a plurality of strap material layers, each overlaid on the lapped first and second panels and having at least one strap lapped and fused thereto.
• the strap material layer or layers are lapped only against the second panel of the rear portion.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, a top strap panel partially lapped against the rear portion, the top strap panel comprising a slot, and a strap extending through the slot and being secured back onto itself.
• the headgear has left and right top strap panels, each partially lapped against respective left and right sides of the rear portion, and each top strap panel comprises a slot with a respective strap extending therethrough and being secured back onto itself.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels, two straps, and two overmold components, wherein the overmold components are each overmolded over a respective one of the two straps to secure the rear portion and straps together.
• the rear portion comprises two slots through the rear portion, the overmold components each further comprise a mounting post having a base and a head, wherein the head of a respective mounting post is inserted through each respective slot to connect the rear portion and overmold components together.
• Each head comprises lateral wings which are wider than a respective slot.
• the headgear includes four straps, and two straps are overmolded by each of the overmold components.
• the rear portion comprises two slots through the rear portion, and respective portions of each of the overmold components are fused to each other through each respective slot.
• the present disclosure provides a headgear for a patient interface, the headgear comprising: a rear portion that has a first and second lapped panels and defines a strap connection region, and a strap located at the strap connection region, wherein at the strap connection region the rear portion is folded over the strap.
• the strap is joined to the rear portion by fusing the rear portion to both sides of the strap.
• the present disclosure provides a rear portion of or for a headgear which is for connection to a patient interface, the rear portion comprising a first and second lapped panels defining a lapped region, and wherein, except for at one or more strap connection regions, an entire perimeter of the lapped region of the first and second lapped panels are fused together.
• a headgear is formed by interposing part of a strap between the first and second lapped panels at each strap connection region and fusing the panels and strap together. The first and second panels about the entire perimeter of the lapped region of the headgear are fused together.
• the present disclosure provides a rear portion of or for a headgear which is for connection to a patient interface, the rear portion comprising a first and second lapped panels defining a lapped region, where, except for at one or more strap connection regions, an entire periphery of the lapped parts of the first and second panels are fused together.
• a headgear is formed by interposing part of a strap between the first and second lapped panels at each strap connection region and fusing the panels and strap together.
• the first and second lapped panels about the entire periphery of the lapped region are fused together.
• the first and second panels at the lapped region of the headgear are entirely fused together.
• the present disclosure provides a headgear comprising a first and second lapped panels, the lapped panels defining a lapped region in which the first and second panels respectively overlap and underlap each other, wherein the lapped panels are fused together such that a straight-line condition between two edges of the lapped region is satisfied, wherein according to the straight-line condition a total length along a line between the chosen two edges of the lapped region which is fused exceeds a total length between the two edges which is unfused.
• the straight-line condition is satisfied between at least one pair of respective upper and lower edges of a lapped region of a rear portion of the headgear.
• the straight-line condition is satisfied along any straight line between an upper and lower edge of a lapped region of a rear portion of the headgear.
• the straight-line condition is satisfied along any line between two edges of a lapped region of a rear portion of the headgear.
• the headgear further defines a non-lapped region in which the first panel is not lapped.
• non-fused portions are located only away both ends of the line.
• a cumulative length along the line at its ends where the lapped portion is fused exceeds a cumulative length along the line where the lapped portion is not fused.
• a cumulative length along the line at its ends where the lapped portion is fused exceeds a cumulative length along the line at a central portion where the lapped portion is not fused.
• headgear is generally referred to in the context of a patient, it will be understood that the term patient may as appropriate be substituted for an assistant to the patient or a medical professional or otherwise anyone else who may use or interact with the headgear, whether for their own use or in association with aiding someone else's use of the headgear.
• plastic shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.
• Figures 1 A and 1 B are cross-sectional views of, respectively, a pre-fused and fused configuration of two panels.
• Figures 2A and 2B are cross-sectional views of another pre-fused and fused configuration of two panels.
• Figures 3A and 3B are cross-sectional views of another pre-fused and fused configuration of two panels.
• Figures 4A and 4B are cross-sectional views of a pre-fused and fused configuration of three panels.
• Figures 5A and 5B are pre- and post-fusing cross-sectional views of two panels.
• Figure 6A is a cross-sectional view of a pre-fused configuration of three panels.
• Figures 6B and 6C show two different fused configurations of the three panels of Figure 6A.
• Figure 7A is a plane view of two panels lapped with each other.
• Figure 7B shows a region about the perimeter of the lapped part of the two panels of Figure 7A where the two panels are to be joined together.
• Figure 7C shows the assembly of Figure 7B, but where the panels and the joining region are relatively misaligned.
• Figure 8A is a plane view of two panels lapped with each other.
• Figure 8B shows a region across the lapped part of the two panels of Figure 7A where the two panels are to be joined together.
• Figure 8C shows the assembly of Figure 7B, but where the panels and the joining region are relatively misaligned.
• Figure 9A is a side view of a welding press for welding a headgear, where the weld press is open.
• Figure 9B is a side view of a welding press for welding a headgear, where the welding press is closed.
• Figure 10 is a view of a headgear retaining an interface to the face of a patient.
• Figure 11 is a lay-flat view of a headgear.
• Figure 12 is a view of two panels.
• Figure 13 is a view of the two panels of Figure 12 lapped with each other to define part of a headgear.
• Figure 14 is a view of the headgear of Figure 13 where the panels have been fused together.
• Figure 15 is a view of a headgear illustrating a boundary within which a fusing may be applied to the panels of a headgear.
• Figure 16 is a close-up view of a part of the headgear of Figure 14, showing the two lapped panels and the boundary of where fusing is applied to.
• Figure 17A is a lay-flat view of a headgear.
• Figure 17B is a lay-flat view of the headgear of Figure 17A with straps joined to it.
• Figure 18 is a lay-flat view of a headgear.
• Figure 18-1 is a lay-flat view of a headgear.
• Figure 18-2 is a view of the headgear of Figure 18-1 worn by a patient.
• Figure 18-3 is a view of four different rear portions for a headgear.
• Figure 19 is a lay-flat view of a headgear.
• Figure 20 is a view of a die to form the headgear of Figure 19.
• Figure 21 is a lay-flat view of a headgear.
• Figure 22 is a view of a die to form the headgear of Figure 21.
• Figure 23 is a lay-flat view of a headgear.
• Figure 24 is a view of a die to form the headgear of Figure 23.
• Figure 25 is a view of another configuration of a die having indicia-forming elements.
• Figure 26 is a view of part of a headgear having indicia formed in it.
• Figure 26-1 A is a view of a headgear and a patient interface.
• Figure 26-1 B is a cross-sectional view through the line A-A of Figure 26-1 A.
• Figure 27 is a lay-flat view of a headgear having indicia formed in it.
• Figure 28A is a pre-fusing lay-flat view of a headgear.
• Figure 28B is a view of the headgear of Figure 28A after it has been fused.
• Figure 29 is a lay-flat view of a headgear.
• Figure 30 is a lay-flat view of a headgear.
• Figure 31 is a lay-flat view of a headgear.
• Figure 32 is a lay-flat view of a headgear.
• Figure 33 is a lay-flat view of a headgear.
• Figure 34 is a lay-flat view of a headgear.
• Figure 35 is a view of the drape configuration of a headgear when held by a patient.
• Figures 36A and 36B are views of a headgear on a patient's head.
• Figure 37A is a panel for part of a strap.
• Figure 37B shows the panel of Figure 37A bonded to another strap panel.
• Figure 38 shows another strap panel.
• Figure 39A and 39B are top and side views respectively of a strap end feature.
• Figure 40A and 40B are lay-flat views of a headgear with stamped parts.
• Figure 40C is a view of a rear portion for a headgear with stamped parts.
• Figure 41 is a partial view of two configurations of a headgear.
• Figure 42 is a view of a continuous fusing process for forming part of a headgear.
• Figure 43 is a view of another continuous fusing process for forming part of a headgear.
• Figure 44 is a view of another continuous fusing process for forming part of a headgear.
• Figure 45 is a view of another continuous fusing process for forming part of a headgear, where the headgear part is stretched before it is fused.
• Figure 46-1 A is a view of a headgear panel and two inserts.
• Figure 46-1 B is a view of two fused panels having pockets formed between them.
• Figure 46-2 is a view of two fused panels having voids formed between them.
• Figure 46-3 is a view of two fused panels having a continuous pocket formed between them.
• Figure 47A is a view of a headgear and interface where the fused headgear panels define air conduits.
• Figure 47B is a cross-sectional view of an air conduit through the line A-A of Figure
• Figures 48A-D are views of steps in a process for joining a strap to another portion of a headgear.
• Figure 49A is a view of panel
• Figures 49B-D are views of illustrated fusing patterns which may be applied to the panel of Figure 49A.
• Figure 50 is a view of part of a headgear.
• Figure 51 is a view of part of a headgear.
• Figure 52 is a view of a rear portion of a headgear.
• Figure 53 is a view of another rear portion of a headgear.
• Figure 54 is a view of a rear portion of a headgear when the headgear is worn by a patient.
• Figure 55A is a view of a fusing arrangement provided to a panel and Figures 55B and 55C show the performance of the fused panel under different loading conditions.
• Figure 56A is a view of a panel which has been pre-stretched and fused
• Figure 56B is a view of the fused panel of Figure 56A when the pre-stretching is released.
• Figure 57 is a view of a headgear and interface when worn by a patient.
• Figure 58 is a view of a headgear and interface when worn by a patient.
• Figure 59 is a view of a headgear and interface.
• Figure 60A is a view of a headgear and interface with an integral adjustment fixture for a strap of the headgear.
• Figure 60B is a partial cross-section through the line A-A of Figure 60A.
• Figure 61 A is a view of a strap with an integral fixture.
• Figure 61 B is a view of the fixture and panels forming the strap of Figure 61 A before the components are joined together.
• Figure 62 is a view of another fixture.
• Figure 63 is a view of two lapped panels configured to provide a smoothed edge.
• Figure 64 is another view of two lapped panels configured to provide a smoothed edge.
• Figure 65 is a view of two lapped panels configured to provide smoothed edges to both sides of a panel.
• Figure 66 is a view of two lapped panels configured to provide smoothed edges to both sides of a panel.
• Figure 67 is a view of two lapped panels configured to provide smoothed edges to both sides of a panel.
• Figure 68A is a view of a headgear and an interface.
• Figure 68B is a cross-sectional view through the line A-A of Figure 68A.
• Figures 69A and 69B are views of a process for forming a slider feature.
• Figure 69C is a view of the panel with a slider feature of Figure 69B, with another panel folded about its edges to smooth them.
• Figure 70A is a view of a panel with fused adjustment features formed in it.
• Figure 70B is a cross-sectional view taken along the length of the panel of Figure
• Figure 71 is a view of a panel with fused adjustment features formed in it.
• Figure 72A is a view of a headgear and an interface.
• Figure 72B is a cross-sectional view through the line A-A of Figure 72A.
• Figure 72C is an illustrated view of a continuous process for forming a headgear portion with a filament in it.
• Figure 72D is a view of two fused panels with a filament slidable between them.
• Figure 73 is a view of a headgear which is adjustable by drawing on filaments provided within portions of the headgear.
• Figure 74 is a lay-flat view of a headgear.
• Figure 75 is a lay-flat view of a headgear.
• Figure 76 is a lay-flat view of a headgear.
• Figure 77A is a lay-flat view of a headgear.
• Figure 77B is a partial view of a headgear such as the headgear of Figure 77A, illustrating the connection of a strap to the rear portion of the headgear.
• Figure 78 is a lay-flat view of a headgear.
• Figure 79A is a lay-flat view of a top strap for a headgear.
• Figure 79B is a lay-flat view of a headgear including the top strap of Figure 79A.
• Figure 80 is a lay-flat view of a headgear.
• Figure 81 is a lay-flat view of a headgear.
• Figure 82A is a partial pre-assembly view of two straps and a rear portion of a headgear with an overmolding component.
• Figure 82B is a lay-flat view of a headgear.
• Figure 83A is a partial pre-assembly view of a strap and rear portion of a headgear.
• Figure 83B is an assembled view of the strap and rear portion of Figure 83A.
• Such a headgear may include a plurality of panels, configured to present the headgear with at least one lapped region in which at least two of the plurality of panels overlap and underlap each other, and at least one non-lapped region in which one or more of the panels are not lapped by another of the panels.
• the panels at one or more of the lapped regions may be joined together, such as by fusing.
• FIG. 1 A to 5C Details of example lapped and non-lapped panel configurations and fusing of those panels will now be described with particular reference to Figures 1 A to 5C. These figures may be taken to illustrate cross-sectional views or partial cross-sectional views of a headgear according to the disclosure, or of various component parts from which a headgear may be built up.
• Figure 1 A is a sectional view of two lapped panels, a first panel 1 and a second panel
• the panels may be selected from any suitable panel-like material.
• This may include textiles being networks of natural and/or artificial fibres, and more particularly fabrics as may be made by weaving, knitting, spreading, crocheting, bonding, or other available methods.
• the panels may also include any other non-conventionally textile materials which may be provided in a panel-like form, such as a plastic or composites.
• the individual panels may according to at least some configurations be single plies or single layers of one material or a unitary composite of materials, as opposed to multiple layers of the same or different materials.
• the panels may be of a sheet-like form or may comprise tubular panels.
• the panels may have a 2D shape.
• one or more of the panels which form the headgear may have a 3D shape.
• some or all of the plurality of panels may be of flexible materials, and particularly materials which may drape under their own weight. Such materials may be particularly suited to forming parts of a headgear which is to conform to the shape of a patient's head.
• Each panel of the plurality of panels that comprise the headgear defines two opposed major faces. In at least some embodiments it may be these major faces which are to be lapped against each other and joined together within the one or more lapped regions of the headgear.
• the plurality of panels may each be panels of the same material.
• the panels may be of different materials. Different panels, such as may include different materials, may define various material properties or characteristics.
• the headgear which is formed from these panels may in turn be defined by these material properties. Where a panel is treated by being fused or lapped panels are fused together, the properties of the respective panels and the headgear may further be altered by the fusing.
• the material properties of a panel include its stretch properties.
• a panel having a relatively greater stretchability has a relatively greater extensibility, and vice-versa.
• the in-plane stiffness of a panel refers to the degree of resistance to in-plane extension or stretch of the panel.
• the flexibility of a panel refers to an out-of- plane stiffness property of a panel, for example the degree to which a panel will drape.
• the extensibility of a panel may be omnidirectional, such that the panel or headgear may have the same in-plane extensibility in all directions.
• the stretch properties of a panel may differ directionally, so the panel has either different extensibilities or is extensible and inextensible in different in-plane directions.
• a stretch panel may be one that has at least some degree of in-plane extensibility.
• a non-stretch panel may be relatively inextensible in-plane in at least one direction.
• the panels may have differing stretch properties from each other.
• a first panel may have a first stretchability, while a second panel has a second different stretchability.
• first stretchability or second stretchability may define a fifth stretchability, which is different to the respective one of the first stretchability or second stretchability.
• a panel which has stretch properties such that it is extensible may or may not, when a stretching load is removed, allow recovery of some or all of the extension.
• the stretch properties of a stretch panel may include recoverability, so that a panel may be stretched then when the stretching load is removed it may return to or towards its original unstretched shape.
• An elasticated panel includes at least one elastomeric, rubber, or rubberised component.
• an elasticated panel may include at least some fibres of such an elastic material.
• a non-elasticated panel is a panel which does not include any such an elastomeric, rubber, or rubberised component.
• An elasticated panel has greater elasticity, due to the at least one elasticated component, than a non-elasticated panel of the same material but without the at least one elasticated component.
• the properties of a panel may include the texture of the panel at one or both of its major faces, or at one or more of the edges bounding the two major faces.
• Another property of a panel may be the softness or hardness of one or both of the major faces or one or more of the edges bounding the two major faces of the panel.
• Further properties which one or more of the panels may have include different densities, surface hardnesses, Young's moduli, thicknesses, colours at one or both of the major faces or bounding edges, coefficients of friction at one or both of the major faces relative to a reference material.
• the different material properties may also include different degrees of breathability, different degrees of hydrophobic or hydroscopic qualities, different permeability, or different transparencies or sheers.
• an individual panel itself may have one or more of such characteristics which are directionally or locationally different within the panel itself.
• a panel may have a directionally different stretch properties.
• a panel may also have directionally different texture or softness, flexibility, or frictional coefficients.
• different panels of the plurality of panels may have different physical configurations, including both thickness and in-plane dimensions.
• Another example of a characteristic of a textile panel may be whether it comprises a cut or uncut pile. Whether the pile is cut or uncut may provide different surface characteristics. For example, an uncut pile may present loops of material at a panel surface. Such a material with an uncut pile may generally be known as an unbroken loop (UBL) material.
• UBL unbroken loop
• loops may be desirable to act as the loop portion of a hook and loop fastener system.
• a hook and loop fastener system may be provided without having to attach any additional loop-providing component to the panel. This may go at least some way to providing a headgear which is of reduced thickness.
• One or more panels to be utilised in the headgear may be unravelable, meaning that their constituent fibres may be unravelled.
• one or more panels to be utilised in the headgear may not be able to be unravelled, what may be known as a free-cut material.
• a free-cut material may be cut and may not or may at least be resistant to unravelling of the constituent fibres along the cut edge.
• Such materials can be cut to shape with the cut edge of the panel forming an edge of the headgear without the need for further processing.
• the panels may be selected of materials having any other material properties or panel configurations such as may provide for the desired functionality of a headgear which is to comprise the panels.
• composite characteristics may be provided at a lapped region where the panels are lapped.
• the respective panel thicknesses will form a lapped region with a thickness equal to the sum of the respective panels.
• one panel at a lapped region is extensible in one direction
• another panel at the lapped region is extensible in another direction which is different or potentially perpendicular to the direction of the former panel.
• the panels are extensible only in directions which are perpendicular or substantially perpendicular to each other, a functionality may be provided where the panels at the non-lapped regions may stretch in their respective directions, but at the lapped region may be substantially inextensible.
• the properties of the headgear may be at least in part determined by different configurations of respectively lapped panels at the one or more lapped regions of the headgear.
• Lapped regions of the headgear may be fully or only partially joined together.
• a lapped region may include both joined regions where the adjacent panel surfaces have been joined together, and non-joined regions where the adjacent panel surfaces are not joined together.
• a direct join between two panels is a join of the two panels to each other, without any other material between the two panels.
• a direct join between two panels would exclude any interposed adhesive or an interposed intermediate layer.
• a direct join may be a join of one or both of the materials of the respective panels to each other.
• At least part of a lapped region of the headgear may have its panels joined by being fused.
• Figure 1 B shows the first panel 1 and second panel 2 of Figure 1 A which have been joined together by being fused.
• Fusing defines a melting of a panel or at least a constituent material of the panel.
• fusing refers to the melting of one or both of the panels into the other or each other, respectively.
• two panels may be fused by either a) melting only one or primarily one panel into the other, or b) a simultaneous melting of both panels into each other.
• a panel which is to be fused should include a meltable material, such as an artificial fibre.
• a meltable material such as an artificial fibre.
• a polymer for example, ethylene glycol dimethacrylate copolymer
• two panels which are to be fused together at least one of the two panels should include a meltable material, such as an artificial fibre.
• the fusing of a panel or panels may be non-additive, in that the fusion involves a treatment applied to the panel or panels and does not involve the use of any additional material such as an adhesive interposed between two panels to fuse them together.
• Fusing may involve one or both of the application of heat and pressure to the panel or panels.
• Fusing may generally be by a welding.
• one or more of the panels is of a weldable material.
• Welding may include forms of plastic welding.
• fusing may be provided by radio frequency (RF) or high frequency (HF) welding, where the material to be fused comprises a dipolar material which is heated and melted by electromagnetic excitation.
• RF radio frequency
• HF high frequency
• materials which may be fused by radio frequency or high frequency welding include PVC, CPVC, Polyurethane, EVA, PVDC, PET, and nylons.
• Fusing by radio frequency or high frequency welding may be provided to materials which at least partially include a dipolar material.
• materials which may be fused by radio frequency or high frequency welding include PETG, TPU, and LDPE.
• One or more panels which are to be fused by welding may thus comprise or consist of a dipolar material, which are weldable by these processes.
• the fusing process such as welding by a radio frequency or high frequency welding
• the panel or panels respectively may generally be caused to consolidate or solidify.
• a panel or panels may be fused to varying degrees.
• one or more of the welding platen separation, weld energy, and welding time may be varied to increase or decrease the degree of the fusing.
• Relatively lower degrees of fusing may cause partial or localised consolidation of the fused material. Relatively greater degrees of fusing may cause more complete or generalised consolidation of the fused material. A material which is exposed to a sufficient degree of fusing may cause the original material, for example a dipolar fabric, to form a solid plastic where it is fused.
• the panels are to be fused by high frequency welding the panels specifically include nylon, and in particular a nylon content of about or more than 80%. A remaining portion of the panel may include spandex or other similar polyether-polyurea copolymers.
• the fabrics may have a density of about 160 g/m 2 or greater.
• the fusing of two panels is at least primarily to be a fusing of the lapped faces of the respective panels.
• Panels joined together by fusion may have different degrees to which they are fused together. This degree of fusion may be defined by peel forces between the fused surfaces; the force necessary to peel the two fused surfaces apart, given some reference peeling angle.
• Panels joined together by fusion may define a fused zone, at which the peel forces required to peel the panels apart are non-zero.
• the peel forces at a fused zone may be significant and may even be such that the panels cannot be peeled apart without destruction of the respective panels.
• Panels joined by fusion may further define a non-fused zone, at which the peel forces to separate the panel are zero or substantially zero.
• panels joined by fusion may define one or more transition zones, at which the peel forces transition between those of the fused zone and the non-fused zone.
• a transition zone may define a gradient of peel forces between that of the fused zone and the non-fused zone.
• a transition zone may be defined by peel forces across its whole area which are between that of an adjacent fused zone and an adjacent non-fused zone.
• a transition zone may additionally or alternatively be defined by a decrease in density of fused area relative to an adjacent fused zone, and thus a relatively lesser average peel force required to separate the two panels than at the adjacent fused zone.
• One or more lapped regions may be fully fused, so an entirety or substantial entirety of the lapped surfaces are joined together.
• the whole of the lapped surfaces may be joined together except for some minor parts such as may for example be used in providing a desired texture or surface finish to the headgear.
• a substantial entirety of the lapped surfaces may be about 90% of the lapped area, or even about 95% of the lapped area.
• one or more lapped regions may be partially fused, defining both fused zones and non-fused zones within the lapped region.
• the fused configuration of panels of a headgear according to the disclosure may be described by a straight-line condition.
• a straight line is drawn between any two edges of a lapped region of the headgear, or portion of the headgear such as a rear portion.
• the length that is within fused areas is greater than the length within non-fused areas. In other words, along the straight line there is more welded length than there is non-welded length.
• the welded length of a line that satisfies the straight-line condition may be anywhere between a majority of the total line length to the entirety of the line length.
• the straight-line condition may be satisfied between two given points, such as between an upper edge of the lapped region and a lower edge of the lapped region of a rear portion of the headgear.
• the straight-line condition may be satisfied between more than two pairs of given points, such as between a plurality of respective upper and lower edges of a lapped region of the rear portion of the headgear.
• the straight-line condition may be satisfied along an entire width of the rear portion of the headgear, between successive locations along the upper and lower edges of a lapped region of the rear portion of the headgear.
• the straight-line condition may be satisfied along any straight line that can be drawn between two points located on an edge or edges of a given lapped region of the rear portion of the headgear.
• the fused and non-fused lengths may be arranged in particular ways. For example, at the ends of the lines adjacent to each respective edge the lapped panels may be fused. In this configuration any non-fused portions along the line are provided along a central portion or portions of the line, away from the line ends. In some configurations along a line that satisfies the straight-line condition non- fused portions along the line are only located away from the ends of the line.
• a cumulative length along the line of the end portions where the lapped portion is fused may be greater than a cumulative length of any central non-fused portions along the line.
• the fusing of a panel or multiple panels may change one or more properties of the panel or panels.
• melting and re-solidification of a material of the panel may cause the panel to be one or more of thinner, denser, more stiff, less stretchable, less recoverable, or of a greater yield strength in stretching. Accordingly, in addition to joining panels together, selectively fusing the headgear at different lapped and non-lapped regions may allow control of the performance of the headgear.
• fusing of particular parts of the headgear may be utilised to create load transfer paths between different parts of the headgear.
• parts of the headgear which are not fused may be located to define stretch zones, or areas of relatively greater thickness or suppleness.
• the fusing of a panel or panels may also change one or more surface characteristics of the panel. For example, where a panel is of an unbroken loop material at a surface, the melting and re-solidification the panel or a constituent material of it may reduce an number of unbroken loops presented at the surface of the panel. This may reduce the effectiveness of the panel in coupling with the hooks of a hook and loop fastener. It may even act to prevent the hooks of a hook and loop fastener system from being able to couple with the panel.
• the selective fusing and non-fusing of parts of panels may provide parts of the same panel or panels which have an unbroken loop surface and others which do not.
• FIG. 2A shows a first panel 1 and second panel 2 lapped with each other to define a lapped region 21 , which have been partially fused together.
• a majority of the lapped region 21 has been fused to define a fused zone 41 , while a remainder of the lapped region is left unfused and defines a non-fused zone 51.
• the panels 1 and 2 are not joined to each other by being fused and have zero or substantially zero peel force required to separate the layers at this zone.
• Figure 2B shows the panel layup of Figure 2A, but where it has a second non-fused zone 52 which separates the fused zone 41 of Figure 2A into a first fused zone 41 and a second fused zone 42.
• the panels may be fused and left unfused at any configuration of different areas to provide the desired characteristics of the headgear.
• the fusing of the panels may result in the thinning of the panel layup at fused zones. This may particularly be the case where the fusing is provided by the application of pressure at the parts of the panels which are to be fused.
• Figure 3A illustrates a layup of a first panel 1 and second panel 2 which have been partially fused to define a non-fused zone 51 and a fused zone 41. At the fused zone the thickness of the layup is less than that of the panels at the non-fused zone.
• Figure 3B shows the same layup as in Figure 3A, but where there are two spaced apart fused zones 41 and 42, and two non-fused zones 51 and 52.
• the first non-fused zone 51 is at an end of the panels.
• the second non-fused zone 52 is located between the two fused zones 41 and 42.
• Figures 1 -3 have illustrated configurations where two panels are fully lapped with each other. Panels also may be arranged in other configurations, such as where one or both panels define a non-lapped region, or where panels are butted against each other edge to edge.
• Figure 4A shows a layup of a first panel 1 , second panel 2, and third panel 3 which illustrates some such configurations.
• first panel 1 and second panel 2 are each partially lapped with each other.
• the third panel 3 then partially laps the second panel 2, and the edges of the first panel 1 and third panel 3 abut each other.
• the arrangement of Figure 4A defines a first non-lapped region 31 , a lapped region 21 , and a second non-lapped region 32.
• Figure 4B shows the arrangement of Figure 4A where the panels are fused together. As seen in Figure 4B the lapped surfaces of the first panel 1 and second panel 2, and the second panel 2 and third panel 3 have been fused together. Also seen in Figure 4B the abutting ends of the first panel 1 and third panel 3 have been fused together.
• the characteristics of the headgear at either a lapped region or a non-lapped region also be influenced by whether or not, and the degree to which, the panel or panels are fused.
• the fusing of a panel by its melting may result in one or more of a localised thinning, reduced extensibility, or reduced flexibility at and potentially also adjacent to the fused zone.
• fused zones of the headgear may be located at both non-lapped regions and lapped regions to provide desired properties to the headgear.
• One or more of the panels at a non-lapped region of the headgear may also be fused. Instead of acting to join together two panels, fusing at a non-lapped region may function to alter the material properties of the panel.
• Figure 5A shows a first panel 1 and second panel 2 which are partially lapped with each other to define a first non-lapped region 31 of the first panel, a lapped region 21 , and a second non-lapped region 32 of the second panel.
• Figure 5B illustrates the result of a fusing applied to both the lapped region 21 and part of both of the first non-lapped region 31 and second non-lapped region 32.
• the fusing is such that it results in a thinning of the panel or panels where it is applied.
• the fusing causes the panels to have a first fused zone 41 of the first panel, a second fused zone 42 of the fused lapped first panel 1 and second panel 2, and a third fused zone 43 of the fused second panel 2.
• the remaining lateral portions of each of the first panel and second panel are not fused and define the first non-fused zone 51 and second non-fused zone 52.
• Panels may be singly lapped, as seen in any of Figures 1 A-4B where a panel is only either overlapped or underlapped by one other panel. When single lapped panels are joined together they form a single lapped joint. Panels may also be double lapped, so that a panel is both underlapped and overlapped on respective major faces of the panel by two other panels. Where double lapped panels are joined together may be referred to as a double lapped joint.
• Figure 6A shows a layup with a first panel which is both overlapped and underlapped, or double lapped, by, respectively, a second panel 2 and third panel 3.
• the layup defines a first non-lapped region 31 , a lapped region 21 at which the first panel is lapped on either side by the second panel and the third panel, and a second and third non-lapped regions 32 and 33 of each of the second panel 2 and third panel 3 respectively.
• Figure 6B shows a first fused arrangement of the layup of Figure 6A, where the lapped region 21 is fused. The fusing of the lapped region 21 joins both the lapped surfaces of, respectively, the first panel 1 and second panel 2, and first panel 1 and third panel 3, together.
• each of the non-lapped regions 31 -33 remain unfused.
• the second and third panels are shown to now be lapped with each other due to the fusing of the adjacent lapped region.
• Figure 6C shows another fused arrangement of the layup of Figure 6A, where the fusing has been applied across the whole section to define a first fused zone 41 of the first panel, a second fused zone 42 of the lapped region 21 , and a third fused zone 43 of the second and third panels, which are now fused together.
• a double lapped joint such as shown in Figure 6B or 6C may have the advantage of reducing the potential for inducing torsion in the joint under lateral loading of the respective panels. Such torsion may cause twisting or other deformation of the joint, so that at least part of the headgear does not lay flat. This may be undesirable in some circumstances, such as where the headgear is to lie flat against a patient's head, because any such torsion of the headgear may result in points of increased pressure against the patient's head, and thus discomfort.
• Reduced or eliminated torsion at an interface between panels may also increase the strength of the headgearwhere the panels are joined or bonded together. Torsion of the panels at a joint may cause them to be subjected to peel stresses when the panels are under tension. Joints may have relatively limited strength under such peel stresses, where the panels are pulled away from each other perpendicularly to the joined surfaces. The reduction of torsion may mean that the panels are not twisted and exposed to peel stresses, but rather to predominantly or only to shear stresses. Some bonds, particularly fused or welded bonds, may be able to provide greater strength under shear stresses than peel stresses. This means that the strength of the headgear may be increased by reducing torsion at lapped panels.
• a single lapped joint may be preferable to a double lapped joint as it may provide a joint of lesser thickness.
• Single lapped joints of the arrangement of Figure 4A and 4B may also function similarly to a double lapped joint in reducing torsion, and thus potentially increasing the strength of the joint, where lateral loads are to be applied to the first panel 1 and third panel 3.
• the periphery of panel, portion, region, or the headgear itself may generally be understood as referring to the perimeter and more particularly a border within the perimeter, of the respective panel, portion, region, or headgear. Where the context requires, this may otherwise be referred to as an internal periphery.
• an external periphery of a panel, portion, region, or the headgear itself will generally be understood as referring to a border outside of the perimeter of the respective panel, portion, region, or headgear.
• Figures 7A-7C show plan views of two panels which are to form part of a headgear.
• a first panel 1 provided under a second panel 2, which is fully lapped by the first panel.
• the panels define a lapped region 21 , which is of the same size as the second panel 2.
• the panels are to be joined together to form part of a headgear. They may be joined by fusing or specifically by welding, as has been described. They may additionally or alternatively be joined at least in part by any number of methods, such as a stitching or by the use of an adhesive. For the purposes of this example the panels are to be joined by being fused together, and particularly by welding.
• Figure 7B shows a shaded boundary representing the weld 70 about the perimeter of the lapped region where the panels 1 and 2 of Figure 7A have been joined.
• Figure 7B illustrates a conventional method of joining two or more panels together, particularly by welding and where a foam layer is interposed between the two panels and it is desirable to minimise an amount of the foam layer that is welded.
• welding the panels about the perimeter of the lapped region 70 may present difficulties due to the narrow nature of the weld and the fine tolerances it necessitates. If one or both of the panels are not placed in their correct locations relative to the weld tool, or if the tool is misaligned relative the panels, the weld may not end up in its desired location.
• Figure 7C shows the arrangement of Figure 7B, but where the weld 70 is misplaced relative to the panels 1 and 2.
• the weld 70 is located partially outside of the bounds of the second panel 2 (at the left-hand side and top of the second panel), and partially only within the bounds of the second panel (at the bottom and right-hand side of the second panel). This may mean that the panels are not suitably joined together.
• misalignments may additionally or alternatively be introduced by the locations of the panels relative to each other.
• misalignment in Figure 7C is illustrated as a translational misalignment it will be appreciated that there may additionally or alternatively be rotational misalignments.
• the issues associated with misalignments may be minimised if the width of the weld 70 is increased, such that expected degrees of misalignment will not cause the join to be located outside of the periphery of the second panel 2.
• the issues may also be minimised if the weld 70 provided to extend past the lapped region of the panels, onto where in a correct alignment only the first panel 1 will be. Flowever, such changes may be contrary to the conventional teaching as they involve increasing rather than minimising the area of the panels which are subjected to welding.
• Figure 8A shows the same arrangement as Figure 7A, with a first panel 1 fully lapping a second panel 2
• Figure 8B shows the same panels where the weld 70 is applied across an entirety of the lapped region 21 , and also extends beyond the lapped region onto the non-lapped region of the first panel 1.
• Figure 8C shows the arrangement of Figure 8B, but where the weld and panels are misaligned from each other. Because the weld 70 is larger than the second panel 2, the misalignment can be compensated for and the entire lapped region 21 is still welded. Additionally, because the weld 70 covers the entire area of the second panel 2 rather than just a boundary about the internal and external periphery of it, the effect of any misalignment on the total welded are of the lapped region may be reduced.
• FIGS. 9A and 9B illustrate a welding apparatus 500, such as a high frequency welder, for use in welding the panels of a headgear.
• a welding apparatus 500 such as a high frequency welder
• the welding apparatus 500 includes top and bottom welding platens 501 and 502. Within the platens are an upper die 503 and lower die 504. The platens are to be movable away from each other to open the dies and together to bring the dies into proximity for welding.
• Panels such as a first panel 1 and second panel 2 are located between the two dies.
• the upper die and lower die each define die faces 506. These faces are brought into proximity with each other across the panels in order to provide the fusing of the panels.
• the die faces will variously interact to provide the fusing of the panel material therebetween.
• a direct thermal welding one or both of the dies may be heated to melt the panels which are pressed between the dies.
• the vibration of the dies at the die faces which contact the panels will heat the panels and provide the fusing of the panels.
• the electromagnetic field provided across the dies is of sufficient strength between the two die faces 506 to excite and melt a dipolar material located between the die 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.
• dies are heated they may for example be heated to about 100°C.
• Such heating of one or both of the dies may increase the temperature of the panels before they are fused. This may increase the effectiveness of the fusing operation.
• One or both of the upper die 503 and lower die 504 may include one or more recesses of the die away from the die face 506.
• the upper die 503 includes a recessed region 505.
• the recess creates a relatively increased distance between the two dies at the recessed region 505. This increased distance may reduce a degree of welding of the materials within the footprint of the recessed region 505. It may even cause the materials within the footprint of the recessed region to remain unwelded or at least substantially unwelded.
• the upper die 503 will not contact the panels at the recessed region 505 and may accordingly not cause the panels to be melted at the recessed region.
• a similar functionality would apply in the case of ultrasonic welding.
• the recess 505 will create a region of reduced electromagnetic field strength and consequently a reduced heating of the panels at the recess 505.
• the recess 505 may be of a sufficient depth as to prevent a melting of one or more materials of the panels at the recess 505. The power supplied to the high frequency welding apparatus and the separation between parts of the two dies may thus be used to control where the panels are to be fused, and to what degree they are to be fused.
• Regions of the dies which are closest to each other during welding may cause the parts of the panels between them to be fused, while parts of panels between less proximate parts of the two dies may be fused to a lesser degree or remain unfused.
• design of one or both dies to design the shape of the die face 506 and location and depth of any recessed regions 505 may allow for control of what parts of the headgear are fused and to what degree they are fused, and what parts of the headgear remain unfused.
• the panels of the headgear are to be placed in the welding apparatus 500 between the upper die 503 and lower die 504.
• One or more of the panels may include alignment features 8 as will be described in relation to Figures 28A and 28B.
• the alignment features may interface with corresponding features of one or both of the dies to retain the panel or panels in their desired location relative to the dies.
• the upper die 503 and lower die 504 may be brought together and the welding of the panels commenced.
• Figure 9B shows the welding apparatus 500 where the platens 501 and 502 and dies 503 and 504 have been brought together to weld the panels 1 and 2.
• the dies may be brought into a predetermined proximity of the panel or panels. In some configurations the dies may apply pressure to the panel or panels, or at least to regions of the panels which are to be welded together.
• the fusing of the panels may be provided in 2D as illustrated in Figures 9A and 9B, where the panels are laid flat or substantially flat between the two dies.
• the panels or parts of the panels may be welded in a 3D shape.
• the dies may have complementary 3D shapes, so that the panels drape in a desired way on the dies.
• the welding may then be applied to the panels when draped in their 3D shape. This may facilitate the forming of a headgear which has a 3D shape.
• one or more layers of a non-stick material such as Teflon ® may be provided between the panels and one or both dies to prevent sticking of the panels to the die or dies.
• Figure 10 illustrates a patient 700 wearing a headgear 10 to retain a patient interface 600 to the patient's face.
• the headgear 10 has an external surface 4 which in use faces away from the patient, and an internal surface 5 (not visible in Figure 10) which in use faces and contacts the patient.
• the external and internal surfaces of the headgear may be the same or different to each other.
• the internal and external surfaces of the headgear may be defined by panels having either the same or different properties. For example, the surfaces maybe coloured or textured differently to each other to aid in signalling orientation of the headgear to the patient.
• the headgear 10 has a rear portion 100 located at a back of the patient's head. Two side straps, an upper side strap 301 and a lower side strap 302 are shown. The side straps connect the headgear to the patient interface 600. As seen in Figure 10 the headgear also has a crown strap or top strap 200 which passes over the head of the patient.
• a corresponding two side straps, an upper side strap 303 and a lower side strap 304, may connect to the hidden side of the patient interface 600.
• a region between the two side straps may define an ear loop 320, illustrated in Figure 11.
• the ear loop 320 comprises a portion of the headgear which extends between each respective upper side strap and lower side strap on one side of the headgear.
• Each upper side strap 301 , 303 passes above the ear, and each lower side strap 302, 304 passes beneath the ear.
• the ear loop 320 is located at least behind the ear.
• the edge of the ear loop between each upper strap and lower strap may be curved or may comprise a plurality of linear edges arranged about a nominal curve.
• the straps may be provided in sufficient lengths either shorter or longer than those shown in Figures 10 and 11 to reach and couple with an interface, given a range of different patient head sizes.
• the headgear 10 may include only two side straps, one strap for connecting to each side of the interface.
• Figure 11 shows a lay-flat view of an embodiment of a headgear 10.
• the headgear 10 has a central region 15 and two lateral sides 16 and 17.
• the central region 15 is for location at the rear middle part of the patient's head, while the two lateral sides 16 and 17 extend use around the patient's head towards respective sides of a patient interface.
• the lateral sides 16 and 17 are be shaped to pass about the ears of a patient.
• a height of the headgear taken in a direction perpendicular to a lateral direction around the head of the patient and shown by the lines 807 of Figure 11 , is larger at a middle of the central region 15 than at part of each of the lateral extensions 16 and 17.
• the lateral extensions 16 and 17 narrow to approximately 30% to 50% of the height of the headgear at a middle of the central region 15.
• the height of the second panel 2 at the middle of the central region 15 and at the narrowed parts of the lateral extensions are approximately equal, while the height of the first panel is greater at the central region 15 than at the narrowed parts of the lateral extensions.
• the headgear 10 has a rear portion 100 and a plurality of straps. Specifically, the headgear 10 has a pair of upper side straps 301 and 303, and a pair of lower side straps 302 and 304. The headgear also has a top strap 200.
• the headgear 10 may comprise a rear portion and two side straps, one for connecting to each side of the patient interface.
• the straps may further be comprised of the same panel or panels as the rear portion.
• One or more, or at least part of one or more of the straps may be formed from one or more fused panels according to the disclosure. Additionally or alternatively, the straps may be formed from another material such as a 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 being fused to one or more of its panels.
• each strap 301 and 303 are each shown in Figure 11 as being formed by the same panel as a respective part of the top strap 200, each strap may be a separate part.
• each of the adjacent straps 301 and 302, and 303 and 304, and an adjacent part of the top strap 200 may be formed from one or more of the same panel or panels as each other.
• top strap 200 may in some forms be a single strap which attaches back to the rear portion 100 of the headgear.
• top strap or straps 200 may be formed from one or more of the same panel or panels as the rear portion 100 of the headgear.
• 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 parts which are joined to the rear portion 100.
• the straps of the headgear may include features 330 to facilitate the tensioning of the straps to the patient interface, or in the case of the top strap 200 to itself. Examples of such features 330 are shown in Figure 10. These features 330 may for example be one half of a hook and loop fastener, where the other half may be provided by a surface of the headgear such as part of a strap or the rear portion.
• headgear may be illustrated without any straps or other features for attaching to the patient interface it will be understood that a headgear or particularly a rear portion 100 of a headgear may include any suitable number or arrangement of straps or other fixtures as desired to facilitate its connection with and adjustment relative to a patient interface.
• Figure 12 shows a first panel 1 and second panel 2 which may form part of a headgear 10 according to an embodiment.
• the panels both have a central region 15 and two lateral sides 16 and 17.
• the central region 15 of the second panel has a cut-out at a lower part of it.
• the cut-out is located between a band 110 of the rear portion and two lower strap connection portions 120a and 120b of the headgear.
• the first panel 1 and second panel 2 may be of the same material or of different materials. Particularly, the first panel 1 may be more stretchable than the second panel.
• Figure 13 shows the panels 1 and 2 of Figure 12 overlaid on each other.
• the second panel 2 is located wholly within the first panel, so that the lapped region 21 defined by the panels has the same dimensions as the second panel.
• the lapped panels define a first non-lapped region 31 about the external periphery of the second panel where there is a protruding border of the first panel 1 , and a second non- lapped 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 so 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% the height of the first panel at that same part.
• the headgear has only the thickness of the first panel 1 at the second non-lapped region 32 it may define a region which is thinner or more extensible than the remainder of the lapped region 21.
• the lower extent of the rear portion is to be located around an upper part of the patient's neck. This is a region which may have considerably variable geometry between people of different anatomies, and thus may be a point of discomfort for patients using a given headgear.
• the non- lapped region 31 may function to allow stretching to accommodate the geometry of a patient's neck. Accordingly, the non-lapped region 31 at the cut-out of the second panel 2 may be characterised as a stretch zone 80.
• the stretching at the stretch zone 80 may be greater than a degree of stretching accommodated by at least adjacent portions of the headgear, and particularly than by the lapped region 21 as seen in Figure 13.
• first panel 1 may fully lap the second panel 2
• first panel 1 may only lap the second panel about a border of the cut-out of the second panel 2.
• the headgear may still provide the previously described stretching function, but the first panel may be of a relatively smaller size.
• the cut-out of the second panel relative to the first panel may be of a substantially semi-circular or crescent shape to define the stretch zone 80, as seen in Figure 13.
• the cut-out may be of increasing lateral size towards the bottom of the headgear, to allow for relatively greater expansion towards the bottom of the headgear to accommodate larger lower neck sizes.
• the first non-lapped part of the first panel 1 about the second panel 2 may be a free edge, without a seam. It may be provided either with some edge treatment, or without any edge treatment.
• any edge treatment of the panel may be provided by the fusing of the panel or panels.
• the absence of a seam and/or any edge treatment of the lower edge may increase the comfort of the headgear for a patient by providing continuous properties, such as stretch, stiffness, and thickness, across the whole of the first panel 1 lapped part with the second panel the whole way to the edges of the first panel.
• first panel 1 beyond the second panel 2 may not be substantially load bearing, when in contact with the head of a patient it may roll or curl away from the patient's head. This may create a region of reducing pressure against the patient's head from the edges of the lapped region to the distal edge of the first panel 1.
• Such a zone of gradually reducing pressure may have an edge softening effect, and provide for increased comfort for a patient, as opposed to a sharp drop in pressure across a hard edge which may make the patient more aware of the presence of the headgear or cause pressure irritation of the tissue at the edge.
• the panels of the rear portion 100 may be fused together to join them and define the or part of the headgear.
• Figure 14 shows the rear portion 100 of Figure 13 where the panels have been fused together, such as by a weld applied to the panels. As illustrated by the shading in Figure 14, the fused zone 41 covers the entirety of the lapped region 21 , such that all the lapped parts of the first panel 1 and second panel 2 are fused together.
• the first non-lapped zone 31 of the border of the first panel is not fused, and as such may retain a softer, more flexible, or more stretchable property than the fused panels at the fused zone 41.
• the headgear may retain a desired degree of comfort about its edges.
• Figure 14 shows the fused zone 41 extending across the whole of the lapped parts of the first panel and second panel
• various embodiments of the headgear may utilise one or more non-fused zones.
• headgear of Figure 14 shows the fused zone 41 only covering the lapped panels
• various embodiments may incorporate the fusing of all or parts of non-lapped regions. This may for example be to obtain the benefits of tolerance to misalignment of the panels or the fusing as described in relation to Figures 7A-8C.
• Figure 15 shows the laid-up panels of Figure 13, illustrating a boundary 70 of area to be fused which extends beyond the perimeter of the second panel 2.
• Figure 16 shows a close-up view of an upper part of the central region 15, at the top of the cut-out of the second panel.
• the boundary 70 of the fusing extends to an external periphery of the second panel, being a margin or border beyond the peripheral extent of the second panel 2.
• fusing is to be applied both within the periphery of the second panel 2, and to the first panel 1 at an external periphery of the second panel 2, being the border between the perimeter of the second panel 2 and the line of the boundary 70. As illustrated in Figure 16, fusing is to be applied to not only a periphery of the second panel 2, but to the entire area of the second panel.
• boundary 70 may be located anywhere between an external periphery of the second panel and within the periphery of the second panel.
• boundary 70 may be located at the perimeter of the second panel 2. Where the boundary 70 is located within the periphery of the second panel 2, a border about the periphery of the second panel will remain unfused.
• the distance a boundary 70 extends beyond the second panel 2 may be chosen according to an expected error in placement of the panels relative to the fusing equipment during manufacturing of the headgear.
• the size of the boundary may be continuous about the external periphery of the second panel. In other configurations the size of the boundary may be variable around the external periphery of the second panel.
• the boundary 70 extending into the first panel 1 may result in a fusing of the first panel, in other embodiments the first panel 1 may be melted to a lesser degree than the second panel or even not at all.
• the first panel may be made of a material having a higher melting point than that of the second panel. Provided that the temperature of the materials when the fusing is provided do not exceed the melting point of the first material, the first material may not be fused when fusing is applied to it.
• the first panel may comprise less of a dipolar material than the second panel or may not comprise any dipolar material. Accordingly, the first panel may not be heated and melted by the high frequency welding which may be applied to it.
• the entire periphery of one or even all lapped regions of the headgear may be fused together. Edges of a lapped region where the lapped panels are not joined together may be unsightly. Un-joined edges of a lapped region may also introduce the potential for an undesired peeling apart of the lapped panels at an adjacent part where they are fused together.
• the entire periphery of each lapped region may be fused.
• the rear portion 100 of a headgear may in some forms be configured to connect directly to a patient interface and may as such define the headgear.
• the lateral ends of the rear portion 100 may be fitted with fixtures to attach to a patient interface or may otherwise be adapted to couple with the patient interface such as by an adhesive on one or both of the rear portion and the interface.
• the rear portion 100 may be of a shape as illustrated in for example Figure 13.
• the rear portion 100 may also have different shapes, such as which may include one or more straps formed from one or more of the panels which make up the rear portion 100.
• one or more straps may be associated with the rear portion in order to provide the headgear 10.
• the straps may be associated with the rear portion 100 by any appropriate method, such as by fusing, gluing, or stitching.
• the panels of the rear portion 100 may be fused together it may be desirable to join the straps to the rear portion also by fusing. This may be conducted in discrete steps, where the straps are fused to the already fused rear portion. It may also be conducted in a single step, where the panels of the rear portion and the straps, whether panels or other materials such as a foam fabric-foam laminate, are all fused together in one operation.
• Figure 17A shows another embodiment of a rear portion 100 of a headgear 10 where the lapped region includes a fused zone 41 and multiple non-fused zones 51 -54.
• non-fused zones may generally be located at parts of the headgear which have relatively increased height. As such, the non-fused zones may be provided while still maintaining an amount of fused area across the lateral dimension of the headgear.
• Figure 17A illustrates an example of this, where a contiguous fused band is provided along at least a significant part of the elongate direction of the headgear.
• a headgear may define a band 110 and a plurality of strap connection portions 120.
• An example of a headgear having a band 110 is shown in Figure 17A.
• the band 110 is a part of the headgear which extends around the patient's head and transfers load between the at least two connection points to the patient interface.
• the strap connection portions 120a-d depend from the band, and the straps either are wholly or partially defined by one or more of the same panels or are connected to them, such as by being fused together.
• first panel 1 and/or second panel 2 may be adapted from that shown for example in any one of Figures 13-17.
• the headgear at the band 110 is largely a fused zone 41 and the strap connection portions are non-fused zones 51 -54.
• the headgear may have a band of relatively reduced stretch, which may transfer loads between the sides of the headgear, and areas of relatively greater stretch at the strap connection portions. This may allow for stretch to accommodate the patient's physiology or different tensions on the straps.
• Figure 17B shows the rear portion 100 of Figure 17A where it has been joined to a plurality of straps 301 -304 and 200. As seen in Figure 17B, the straps have each been sandwiched between the first panel and second panel at each of the strap connection portions 120 and the first panel, respective strap, and the second panel have all been fused together at their overlapped parts.
• the fusing of the headgear at the strap connection portions 120 will result in a fusing each of the first panel 1 and second panel 2 to respective sides of each respective strap.
• Sandwiching of the straps between the first layer 1 and second layer 2 may provide the earlier described benefits of a double lapped joint and the consequent ability to reduce torsion at the joint under loading of the straps.
• the headgear 10 as shown in Figure 17B may be first formed as the rear portion 100 of Figure 17A, then the straps joined as separate step. In other forms one or more of the straps may be joined to the respective panels in the same step as part or all of those panels are fused to form the rear portion 100 of Figure 17A.
• any embodiment of a rear portion 100 described herein having a non-fused zone of the lapped panels at a strap connection portion may be wholly or partially fused there when the straps are joined.
• FIG. 18 Another embodiment of a rear portion 100 is shown in Figure 18, where the non- fused zones 51 -54 are all enclosed within an uninterrupted fused zone 41 of the lapped panels 1 and 2.
• the fused zone or zones may be discrete or two or more fused zones may define an uninterrupted fused area, as is seen in Figure 18.
• the enclosing fused parts of the panels may affect how loads are transferred through the headgear, as loads may be transferred from the straps to the fused strap connection portions, and then through the fused portions of the band of the headgear.
• the non-fused zones within the fused zone 41 of Figure 18 may be of relatively greater stretch than the fused zone 41.
• the placement of the non-fused zones 51 -54 at the widest parts of the lapped region may reduce the overall resistance of the lapped regions at those parts to stretch.
• the size of a non-lapped part of the first panel 1 may be the same or substantially the same about the remainder of the non-lapped part of the first panel.
• non-lapped parts of the first panel other than the stretch zone 80 may vary in size.
• the non-lapped amount of the first panel 1 at an ear loop 320 may be greater or less than a non-lapped amount of the first panel 1 at an opposite side of the headgear around a top of the band part 110 of the headgear.
• the size of the non-lapped part of a first panel 1 about the second panel 2 may be referred to as a border of the first panel.
• the border formed by the non-lapped parts first panel 1 about the ear loops 320 and along the upper edge of the rear portion 100 is of a substantially continuous width.
• border in Figure 18 about the ear loops 320 and the upper edge of the rear portion 100 are of substantially the same size, in other configurations the border may be different widths in different regions. Customising the width of the border of non-lapped panel allow for providing local variation in the edge softness of the headgear when worn. Where the first panel is a stretch material, controlling the width of the border of non-lapped panel at different regions may allow deformation along the border to be controlled and recovered, such may occur at the stretch zone 80.
• the first panel 1 may have a locally increased width of the non-lapped border at the or part of the ear loops 320. This may function to prevent or limit the headgear from lifting away from the patient's head when worn.
• Figures 18-1 and 18-2 are, respectively, a lay-flat view of another embodiment of a headgear 10 and a partial rear view of the headgear 10 when worn. As seen in Figure 18-1 the non-lapped portion of the first panel 1 at the sides of the ear loop adjacent the stretch zone 80 are of a locally increased width.
• the non- lapped portion of the first panel 1 has a greater radius of curvature, such that the non-lapped portion between the connection portions 120 and the band 110 defines a crescent shape.
• FIG. 18-2 When worn by a patient, such as illustrated in Figure 18-2, the forces acting on the headgear 10 may in at least some circumstances urge the headgear to lift away from the patient's head at or towards the base of the curve between the strap connection portions 120 and the band 110, behind the patient's ears. If the headgear experiences these forces, the locally widened portions of the non-lapped first panel may aid in limiting or preventing the headgear from lifting away from the patient's head between the strap connection portions 120 and the band 110.
• Figure 18-3 shows four different configurations 10Oa-d of a rear portion 100 of a headgear 10.
• Each of the rear portions 10Oa-d have a first panel 1 which is partially lapped by a second panel 2, with a non-lapped portion of each first panel 1 forming a border about various parts of the periphery of the rear portion.
• the non-lapped portions define a border at the rear stretch zones 80 and a border 83 at the ear loops 320.
• each of the rear portions 10Oa-d illustrate different configurations of the width of the non-lapped border of the first panel 1 at the ear loops 320.
• Such different widths of the border may be provided by increasing the local size of the first panel 1 , or as in the configuration of Figure 18-3 by decreasing the local width of the lapping second panel 2.
• the second panel 2 at the ear loops 320 is of a relatively decreased width.
• the border 83 is approximately half the width of the adjacent part of the second panel 2.
• the border 83 is approximately the same width as the adjacent part of the second panel 2.
• the border 83 is approximately double the width of the adjacent part of the second panel 2.
• the border 83 is approximately three times the width of the adjacent part of the second panel 2.
• first panel 1 is a stretch panel and the second panel 2 is a non-stretch panel
• decreasing the width of the second panel 2 at the ear loops 320 may increase the ability of the headgear to conform in this region to the shape of the patient's head.
• FIG 19 Another embodiment of a headgear is shown in Figure 19.
• a substantial entirety of the lapped part of the headgear is fused to define a fused zone 41.
• the fused zone 41 may extend beyond the second panel 2 and may encompass part or all of the non-lapped region of the first panel 1.
• the headgear of Figure 19 has non-fused zones 51 -54 which are provided as a cluster of multiple small zones. As seen in Figure 19 each small zone is circular; this shape may minimise tight geometries and accordingly reduce the risk of arcing or burning of the panels around the boundary of each small non-fused zone and the fused zone.
• Figure 19 will provide a headgear surface with clusters of raised dots or bumps at each of the groups of non-fused zones 51 -54.
• This may provide a tactile feature for a user, such as helping the user orient themselves to the headgear by the feel of the raised bumps.
• the cluster of small adjacent non-fused zones may also act together to create a stretch zone at which the headgear may have relatively increased extensibility.
• the raised bumps at the non-fused zones may be more prominent at one or the other of the internal and external surfaces of the headgear by the selection of different panel materials. For example, relatively more prominent bumps may be formed at the external surface of the headgear than at the internal surface of the headgear where the panel at the external surface is compressed more by fusing than the panel at the internal surface.
• a given size of a headgear may have certain dimensions and proportions of the rear portion 100, and also certain strap lengths.
• the straps may be lengthened. This may allow the headgear to fit patients having larger geometries. However, straps long enough to accommodate larger patients may cause issues for users of the same size headgear who have smaller geometries.
• the strap ends may return back past the base of the strap. This may make a given size of headgear unsuitable for patients with smaller geometries.
• one or more non-fused zones may be utilised to maintain an area of unbroken loops. This may for example allow the fixing of a strap fixture to the headgear at the one or more non-fused zones.
• the cluster of small non-fused parts of the headgear at each of the non-fused zones 51 -54 may provide sufficient density of unbroken loops to allow the fixing of a strap fixture having a hook part of a hook and loop fastener to the headgear at one or each of the non-fused zones 51 -54.
• the location of one or more non-fused zones may be such as to provide an extension of the region to which a strap fixture may be fixed.
• the first non-fused zone 51 and fourth non-fused zone 54 are each located along a line of extension from parts of their respective straps 301 and 200 and 303 and 200.
• at least part of the second non-fused zone 52 and third non-fused zone 53 is located at a line of extension from their respective straps 302 and 304.
• a non-fused zone may be positioned along a line of extension from a strap at a respective strap connection portion 120 or along a line of extension from any other distal part of the strap, it will be appreciated that a non-fused zone may be located anywhere on a headgear that corresponds to where it is desired for a user to be able to attach a strap fixture.
• the rear portion 100 of Figure 18 shows a further example of non-fused portions 51 -54 which may allow for attachment of a strap fixture.
• the middle non- fused zones 52 and 53 encompass a significant portion of the lapped parts of the panels adjacent the strap connection portions.
• the fused zones 51 -54 are shaped so they increase along a notional line of extension from where straps would be connected to their strap connection portions, such as is illustrated with the straps of Figure 17B.
• Non-fused zones to which a strap can be affixed may be located directly adjacent to the base of a strap.
• the non-fused zone or zones may be located within the fused perimeter but as close as practicable to the base of a strap. This may prevent or minimise strap lengths at which the strap fixture cannot be fixed to the non-fused zone.
• the fixture of the strap end may be sized so as to be able to span the gap between strap base and the non-fused zone.
• a strap fixture of the strap 302 may be of greater size along the length of the strap than the dimension of the fused zone 41 between the base of the strap 302 and the non-fused zone 52.
• Figure 20 illustrates a configuration of a die of a welding apparatus 500, for example either an upper die 503 or lower die 504 for use in fusing a headgear as shown in Figure 19.
• the die 503 has a die face 506 which corresponds to the size and shape of the desired fused zone 41 of the headgear.
• a plurality of small circular regions 505 are recessed from the die face 506. At these recessed parts the die may press less strongly or not press against the adjacent panel of the headgear during fusing. This may result one or both of a reduced compression of the panel adjacent the die at the recessed parts and a decreased degree of or no welding of the panel or panels at the recessed parts.
• Figure 21 illustrates a further embodiment of a fused headgear
• Figure 22 shows an example of a die 503 which may be used to manufacture the fused headgear of Figure 21.
• the headgear may have a transition zone of a fused panel or panels.
• a transition zone the degree of fusion of the panel or panels may transition between that of a non-fused zone and that of a fused zone.
• a transition zone may be located between a non-fused zone and a fused zone.
• transition zones may be provided within a non-fused zone or within a fused zone, or between two non-fused zones or between two fused zones. In such cases the transition zones may define an area of partial fusing of the panel or panels.
• Figure 21 illustrates a fused headgear 10 having a fused zone 41 across a band part of the headgear, and four non-fused zones 51-54 at strap connection portions of the headgear.
• the headgear also has a set of second fused zones 42a-d which are provided as a cluster of small individual zones. These are the inverse of the non-fused zones of the headgear of Figure 19, and instead define spots of material which are fused.
• These may for example be formed by a spot welding of the headgear.
• the second fused zones 42 define spot indents or recesses in the headgear.
• the lateral second non-fused zones 42a and 42d are of a triangular overall shape, which tapers inwardly towards the central portion of the headgear.
• the base of the triangular shape is located adjacent to the respective strap connection portions 51 and 54, while the tip of the triangle is located away from the respective strap connection portions 51 and 54.
• the narrowing part of the second non-fused zones 42a and 52b are located within the transition zones 61 and 64 respectively.
• the second non-fused zones 42b and 42c are also of a substantially triangular shape. Flowever, unlike the second non-fused zones 42a and 42d, the second non-fused zones 42b and 42c are oriented so that their narrowed part is located towards their associated strap connection portions 52 and 53, and the opposite base part is located towards the band of the headgear.
• the wider parts of the second non-fused zones 42b and 42c are located within the transition zones 62 and 63, rather than the narrowed part of the second non-fused zones 42a and 42d in relation to their respective transition zones 61 and 64.
• the second non-fused zones 42a and 42d are of greater size adjacent to their respective strap connection portions 51 and 54 than the second non-fused zones 42b and 42c adjacent to their respective strap connection portions 52 and 53.
• the size of a fused zone comprised of a cluster of smaller fused parts or spots may be either greater or less than those shown in Figure 21. Similarly, the size of the smaller fused parts and their proximity to one another may be either greater or less than what is illustrated in Figure 21.
• fused parts may be uniform or non-unform in size and relative location to each other.
• Each smaller fused part may be fused to the same degree, such as is seen in the illustration of Figure 21.
• one or more of the smaller fused parts may be fused to a relatively greater or lesser degree.
• the degree of fusing of the smaller fused parts may vary across a fused zone which is made up of a cluster of smaller fused parts. For example, a degree of fusion may decrease towards one or more sides of the fused zone, or may decrease towards the entire periphery or perimeter of the fused zone.
• the size and shape of the smaller fused parts and their density and arrangement within a fused zone 42 may be such as to provide a desired pattern or texture to the headgear or part or parts of the headgear.
• fused and non-fused zones may be utilised to customise and particularly to localise properties of the headgear such as breathability, its ability to wick moisture, its edge properties, hand feel, drape, and its stretch and recovery.
• clusters of fused spots may be used to give the headgear a waffle texture.
• a waffle texture may include a pattern of depressed spots.
• clusters of non-fused spots may be used to give the headgear an inverse waffle texture.
• the headgear of Figure 21 further has four transition zones 61 -64. These are each located between an associated one of the non-fused zones 51 -56 and a part of the fused zone 41.
• the first and second panels 1 and 2 may be fused together to a degree between that of the fused zone 41 and that of any of the non-fused zones 51 -54.
• a transition zone may define a single degree of fusion, for example where the panels are fused together to have approximately half the peel strength of a fused zone.
• the shapes of transition zones 61-64 may vary. As shown in Figure 21, transition zones 61 and 64 vary in size from being narrow narrower at a more central part of the headgear to a wider configuration the non-fused end. Conversely, as shown in Figure 21 the transition zones 62 and 63 have a widest dimension at a part that is most central on the headgear.
• a transition zone may define a graduation in the degree of fusion.
• the transition zone 62 may have a first relatively lesser degree of fusion adjacent to the non-fused zone 52 and a second relatively greater degree of fusion adjacent to the fused zone 41.
• the degree of fusion may do so in steps or by a gradient.
• the gradient may be continuous, or it may vary across the transition zone.
• transition zones particularly where the degree of fusion varies across the transition zone, a smoothing effect may be provided between the properties of adjacent fused zones and non-fused zones.
• a transition zone may graduate the transition between these different properties. This may provide for one or more of improved performance, increased comfort, or improved feel of the headgear.
• the comfort and also performance of the headgear may particularly be affected by the use of transition zones. Changes between different regions of the headgear, for example a relatively less extensible and load-carrying part and an adjacent relatively more extensible part of the headgear may induce pressure concentrations at the boundary when the headgear is worn by a patient. Even where pressure concentrations are not induced, the sharp transition between regions of different properties may create a pressure sensation for a patient along the boundary.
• transition zones may allow for graduation in the change of properties of the headgear between two different regions, and accordingly may provide for increased comfort fora patient.
• Loads may be applied in use from the strap connection portions at the non-fused zones 51 -54 and loads may be transferred to the band of the headgear at the fused zone 41. Accordingly, the location of the transition zones 61 -64 of the headgear of Figure 21 are in between the non-fused and fused zones and may as such provide for a graduation in at least extensibility of the headgear along the load transfer paths.
• Various versions of the headgear 10 of Figure 21 may be provided with or without one or more of the sets of second fused zones 42.
• the set of second fused zones 42 may act to pin the panels together at that part of the associated non-fused zone 51 -54 and transition zone 61 - 64. This may prevent an undesired separation of the first and second panels.
• the set of second fused zones 42 may additionally or alternatively also act as a transition element, effectively increasing a density of fused area or an average degree of fusion within the associated non-fused zone 51 -54 and transition zone 61 -64.
• the headgear of Figure 21 may have one or more straps attached to it.
• side straps 301 -304 and potentially also top straps 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 panels of the rear portion of the headgear by any desired method, such as by fusing, by an adhesive, or by use of a fixture.
• the straps may be fused to one or both of the first panel 1 and second panel 2.
• one or more straps such as are illustrated in Figure 11 may be sandwiched between the free ends of the first panel 1 and second panel 2 at the non-lapped regions 51 -54, and the panels and strap fused together.
• a weld die 503 used to fuse the rear portion of the headgear similar to that of Figure 21 is shown in Figure 22.
• the die has a die face 506 which corresponds to the fused zone 41. It also has four recessed regions 505 which correspond to the four non-fused zones 51 - 54.
• the transition zones 61 -64 of the headgear are defined by the sloping transition regions 509 of the die, which graduate from the level of the recessed regions 505 to the level of the die face 506.
• the set of second fused zones 42 are defined by the plurality of posts 507 which are at the level of the die face 506 and are defined by the recessed parts of the die.
• the posts 507 may rise up to the same level as the die face 506.
• the posts 507 may extend to some level between that of the recessed level 505 and the die face 506.
• the posts 507 may be all of the same height. Alternatively, one or more of the posts may be of different heights.
• the height of the posts may vary from a side of each second fused zone which is adjacent a non-fused zone to a side of each second fused zone which is adjacent a fused zone.
• the height of the posts may increase towards a fused zone, so as to an increasing degree of fusion at the posts towards the fused zone.
• the transition zones of a headgear may have a gradient of their degree of fusion in one direction, such as is illustrated in the transition zones 61 -64 of the headgear Figure 21. Flere the degree of fusion increases towards away from the adjacent non-fused zone and towards the fused zone at the band of the headgear.
• Figure 23 shows an example of a headgear 10 of a similar configuration to that of Figure 21 , but where the transition zones 61 -64 have a gradient of fusion about their entire perimeter.
• a die for making a headgear of the configuration of Figure 23 is shown in Figure 24.
• transition regions 509 each define smooth curves of die height between the recessed regions 505 and the die face 506.
• a headgear made using such a die may have increased comfort, as all transitions between welded and non-welded parts of the headgear with their different properties may be gradual rather than abrupt.
• a headgear may include one or more user identifiable indicia, such as a brand, a model name or number, sizing information, a serial number, regulatory information, or other such features. Such indicia may conventionally be additively applied to the headgear, for example by stitching or adhesion of a label.
• Figure 25 shows another die for use in manufacturing a headgear.
• the die 503 of Figure 25 additionally comprises a set of indicia features 508.
• the indicia features 508 are a combination of regions at the die face 506, at a recessed height, and potentially at various transition heights therebetween. By the combination of such features one or more indicia may be formed into the headgear when the panels are fused.
• the indicia may be identifiable from the resulting combination of fused, non-fused, and potentially transition zones. For example, where the panels are made thinner when they are fused, the indicia may be identifiable in the combination of relatively raised and lowered parts of the headgear.
• the indicia may additionally or alternatively be identifiable through differences in these features.
• Figure 26 shows a partial view of a fused headgear 10 having an indicium 9 formed in it by fusing with a die having indicia features 508 such as those of the die of Figure 25.
• the indicia 9 is defined by a non-fused zone 51 and separate fused zones 41 -43 which form the shape of the component letters or symbols of the indicia, in this case a brand.
• the indicia 9 may be formed without a surrounding differentiating part as with the non-fused zone 51 in Figure 26. In such a case the component letters or symbols of the indicia would be defined by a non-fused zone, so as to distinguish the surrounding fused parts of the headgear.
• the application of an indicia by fusing of the panels may be provided as a separate step to the fusing of the panels to join them together.
• the forming of the indicia may be done in the same step as the fusing of the panels to join them together. This may allow fora simplification of the manufacturing process, as the indicia does not need to be provided as a separate manufacturing step.
• indicia 9 may be provided at any desired location of the headgear.
• the headgear may be fused so as to present the indicia at one or both of the internal or external surfaces of the headgear.
• indicia may be formed by selectively removing material of a panel or panels.
• Figure 26-1 A shows a headgear 10 which includes an indicia 9.
• Figure 26-1 B shows a cross-section through the line A-A of Figure 26-1 A.
• the headgear at the cross-section has a first panel 1 which is partially lapped by a second panel 2.
• the first panel 1 however has had material removed from it to form the shape of the indicia 9.
• the first panel 1 and second panel 2 have been fused together to define the indicia 9 in relief through the removed material.
• Such a configuration may provide a clearly visible indicia particularly where the first panel 1 and second panel 2 are of different colours or surface textures.
• Figure 27 shows another embodiment of a headgear 10 which includes a fused indicium 9.
• the headgear 10 has non-fused zones 51 and 52 at the strap connection portions 120a and 120b at the lateral ends of the headgear and is fused at the two more central strap connection portions 120c and 120d.
• the indicia 9 is located centrally at the lapped part of the first panel 1 and second panel 2 above the cut-away of the second panel 2.
• One or more straps may be attached to the headgear of Figure 27 as previously described. While the first panel and second panel are fused together at the lower strap connection portions 120c and 120d the fused panels may be lapped against a strap and fused together with it.
• the panels to form the headgear may need to be placed in the welding apparatus in particular positions relative to each other and to the dies of the welding apparatus. This may be necessary to provide the desired configuration of lapped and non-lapped regions of the headgear, and to provide the desired location of fused and non-fused zones.
• Figure 28A shows an embodiment of a layup for a headgear before it is fused.
• the layup includes a first panel and fully lapped second panel 2.
• the first panel 1 includes a number of alignment features 8 which are provided on a sacrificial part 7 of the first layer.
• the alignment features, holes in the embodiment of Figure 28A may mate with corresponding features of the die or dies of the welding apparatus. This may allow the first panel to be placed in a desired location relative to the dies.
• both the first panel 1 and second panel 2 may include alignment features.
• the alignment features may be discrete or may overlap with each other such when the panels are lapped in their intended positions.
• both the first panel and second panel may have alignment features that are co-extant when the panels are located relative each other in their desired positions.
• the sacrificial parts 7 may themselves act as the alignment features, for example by aligning with some part of the die or dies.
• the sacrificial parts 7 are to be separated from the panel or panels before the manufacture of the headgear is completed.
• the separation of the sacrificial parts may be by, for example, a stamping or cutting of the sacrificial parts away from the remainder of the panel or panels.
• the sacrificial parts may be stamped to separate them from the panels, and the step of stamping may be integrated with the step of fusing the panels together.
• the dies may include a cutting surface which may act on the panels when the dies are brought together to fuse the panels.
• the sacrificial parts may be separated by a melting or burning of the panels during the fusion of the panels, for example in the case of high frequency welding by allowing an arcing between the dies where the sacrificial parts are to be separated from the remainder of the panels.
• the alignment features 9 may not be provided on a sacrificial part which is removed from the layup, and instead are provided on or within the rear portion of the headgear itself.
• one or both of the panels may include one or more holes for alignment of the panels, and those holes remain a feature of the headgear when it has been fused.
• Figure 28B illustrates the headgear 10 of Figure 28A after it has been fused and stamped.
• the headgear includes a main fused zone 41 , sets of spot welds 42, and four non- fused zones 51-54.
• stamping or cutting may be employed to separate sacrificial parts from the headgear to facilitate alignment of one or more panels as previously described, other parts of the headgear may additionally or alternatively be stamped or cut.
• the headgear may have material removed from it by cutting or stamping. This may include either or both of removal of peripheral parts of one or more panels, and the removal of internal parts of one or more panels.
• parts of a lapped region and particularly of a fused zone of a lapped region may be removed from the headgear.
• the removal of these parts may for example reduce the weight of the headgear.
• the removal of parts may also improve the breathability of the headgear.
• Cutting or stamping of one or more of the panels of the headgear may also be configured to create one or more indicia such as a brand, a model name or number, sizing information, a serial number, regulatory information, or other such features.
• Cutting or stamping of one or more of the panels of the headgear may create an indicia by making one or more holes through the headgear in the shape of the indicia.
• An indicia may additionally or alternatively be formed by removing part of one layer at a lapped region. The indicia may then be identifiable through the surface features of the headgear where the material has been removed. The indicia may be identifiable through colour or texture where the lapped layers are of different colours or textures.
• the indicia is cut or stamped into one panel at a lapped region, it may be possible to provide an indicia which is identifiable or at least primarily identifiable from only one side of the headgear. For example, where a panel to be most proximate to the user at the inside surface of the headgear is stamped while an adjacent panel or panels towards or at the external surface are not stamped, the indicia may only be displayed at the inside surface of the headgear.
• Any removed parts of the headgear may be removed prior to the fusing of the headgear.
• Parts of the headgear may be removed in the same step as the fusing of the headgear, such as by a die-cutting of the headgear which occurs when the fusing is applied.
• parts of the headgear may be removed subsequently to the fusing of the panels, either by a die cutting or any other suitable method.
• the removal of material only within fused zones may maintain the fused periphery of the lapped region or regions.
• Parts which are removed from the headgear may be of any suitable size and shape.
• Figure 40A shows the headgear 10 of Figure 17B which has been joined with a plurality of straps 301 -304 and 200.
• the headgear 10 of Figure 40A illustrates how the headgear may be stamped through both the first layer 1 and second layer 2.
• the headgear includes a cluster of first cut-outs 91 of a first size, and a cluster of second cut-outs 92 of a second, greater, size.
• the cut-outs 91 and 92 of Figure 40A pass through both the first panel 1 and second panel 2, to define a cut-out through the whole of the headgear.
• Such cut-outs may reduce the weight of the headgear. They may also increase the breathability of the headgear.
• cut-outs 91 and 92 of Figure 40A may be provided to each of the first panel and second panel individually before they are fused.
• cut-outs 92 and 92 of Figure 40A may be provided to the first panel and second panel together, either before they are fused, as part of the fusing process, or after they are fused.
• Figure 40A illustrates the cut-outs at lateral parts of the band 110
• the cut-outs may be provided in any desired location on the headgear, and particularly where there is a desire to increase breathability of the headgear.
• single cut-outs or clusters of cut-outs may be provided in any number of desired sizes and groupings.
• Figure 40B shows the headgear of Figure 40A, but with a different configuration of cut-outs. As seen in Figure 40A the headgear has a plurality of first cut-outs 91 of the second layer 2. Within the first cut-outs 91 and of a relatively smaller size, there are then respective second cut-outs 92 of the underlapped first panel 1.
• This configuration may provide for increased reductions in weight relative to through holes of the size of the smaller cut-outs 92.
• first panel 1 is a more stretchable than the second panel 2
• configuration of Figure 40B may also provide for localised regions of increased stretch within each cut-out 91 of the second panel 2.
• the larger cut-outs may be formed in the relevant panel before the panels are lapped with each other
• the smaller cut-outs that pass through both panels may be formed once the panels have been lapped with each other, either before, during, or following the fusing of the panels.
• Figure 40C shows another embodiment of a headgear with cut-outs.
• Figure 40C shows the rear portion 100 of Figure 13, but from an opposite side.
• Figure 40C shows the patient-facing inside of the headgear.
• FIG. 40C Also shown in Figure 40C are a number of third cut-outs 93. These are cut-outs of the first layer 1 , so that a region of the second layer 2 is exposed but no hole is defined through the headgear.
• a headgear according to the disclosure may provide for one or more stretch zones 80.
• the headgear may provide for a relatively greater amount of extensibility than at adjacent parts of the headgear.
• the shape, size, and location of such stretch regions may allow for customised functionality of the headgear.
• the stretch regions may be oriented to allow additional extensibility of the headgear in one direction, but not in another.
• the stretch regions may be configured to induce a relative rotation in parts of the headgear either side of the stretch region when there is a load applied across the stretch region.
• Figure 29 shows an embodiment of a headgear fused from a first panel and second panel 2a, third panel 2b, and fourth panel 2c which are lapped to the first panel.
• Each of the second, third, and fourth panels may be of the same material or may alternatively be formed from two or three different materials.
• the third panel 2b and fourth panel 2c are located on the first panel 1 spaced laterally apart from the second panel 2a.
• the gaps between these panels define a first and second stretch zones 81 and 82.
• the headgear consists only of the first panel 1.
• the first panel may be of a material which is relatively more extensible than the second (and third and fourth) panels, or at least which is just more extensible at its non-lapped regions where the stretch zones are than at the lapped regions where the panels have been fused.
• the stretch zones 81 and 82 are of substantially continuous lateral size and extend across the whole height of the band of the headgear.
• the headgear When a load is applied across the headgear in the direction of the arrows 801 and 802 the headgear may stretch and extend in that direction due at least in part to extension at the stretch zones 81 and 82.
• the headgear is stretched an upper part of the headgear extends relatively more than a lower part of the headgear.
• Figure 30 illustrates an embodiment of the headgear 10 where two stretch zones 81 and 82 are configured to allow greater stretch towards a top of the band of the headgear than towards its bottom.
• the stretch zones 80 and 81 are of greater width towards the top of the band than at the bottom. Accordingly, when loads are applied to the direction of the arrows 801 and 802 the lateral ends of the headgear beyond the stretch zones 81 and 82 may be rotated at least some amount in the direction of the arrows 803 and 804.
• Allowing more stretch at one part of the headgear 10 may be desirable to facilitate particular movements of the patient. For example, when a patient wearing the headgear lowers or raises their head, the distance between the top of the rear portion of the headgear and top attachment point to the patient interface and the distance between the bottom of the rear portion of the headgear and lower attachment point to the patient interface may change unequally. Accordingly, a greater stretchability at the top or bottom of the headgear may be desirable. While Figure 30 illustrates a configuration where the stretch zones have a stepped size along the lateral direction of the band, stretch zones may be provided that additionally or alternatively continuously vary in size along the lateral direction of the band. An example of this is shown in Figure 31 , where the stretch zones 81 and 82 are relatively narrower towards an upper part and relatively wider towards a lower part of the band of the headgear.
• the stretch regions are wider at their lower parts, when a load is applied in the direction of the arrows 801 and 802 the lateral parts of the headgear may be induced to rotate at least somewhat in the direction of the arrows 805 and 806.
• An allowable amount of stretch of the headgear may be controlled by varying the size of the stretch zones and the stretch properties of the first panel 1.
• Stretch zones may also be provided in curved shapes, such as is illustrated by the stretch zones 81 and 82 of Figure 32.
• Figure 33 illustrates a further embodiment where the curved stretch zones are oriented oppositely to that of Figure 33, with the stretch zones 81 and 82 curving in towards the centre of the headgear.
• the stretch zones 81 and 82 are also of larger lateral dimension towards their centre than at their upper and lower ends. This may allow a relatively greater degree of stretch at the middle of the stretch zones 81 and 82.
• stretch zones which extend vertically across a whole height of part of the headgear to allow lateral stretch of the headgear
• stretch zones may also be arranged laterally across the headgear to allow vertical stretch of the headgear.
• a stretch zone may be provided laterally across the fused zone of a headgear adjacent to a lower strap connection portion. This may allow additional vertical stretch in the headgear when load is applied to a connected strap.
• a headgear may include one or more stretch zones. As illustrated in the configurations of Figures 29-33, these stretch zones may bisect the fused parts of the headgear, resulting in multiple separate fused zones.
• stretch zones may be provided that do not bisect the fused parts of the headgear, so that the fused zone of the headgear is one contiguous region.
• the headgear may have one or more contiguous fused zones between two or more strap connection portions of the rear portion of the headgear. As loads are transferred between the straps of the headgear in use, a contiguous fused zone between two strap connection portions may aid in effectively transferring loads through the headgear.
• the rear portion 100 of Figure 14 has a contiguous fused area of the first and second panels within the fused zone 41 between the lateral strap connection portions 120a and 120d.
• the rear portion 100 defines contiguous regions of the fused zone 41 between each of the strap connection portions 120a-d.
• the panels of the headgear may be configured to give a particular overall shape or structure to the headgear, which it may have when it is not being worn. This shape may be created by an existing 3D shape of the panels before they are fused, or by the fusing of the panels, or both.
• Such shapes or structures may be important for signalling to a patient or person who will apply the headgear to a patient the nature of the various parts, and their intended orientations for donning.
• the headgear at rest presents an opening between the straps of each side within which the patient's head may be received.
• the headgear at rest presents the side straps as distinct members, projecting away from the remainder of the headgear and potentially also individually of each other, to allow easy identification and grasping of each strap by the patient so that they may be connected to the patient interface.
• This shape and structure may for instance be demonstrated when the headgear 10 is held by a patient, or particularly when a portion of the headgear is grasped by the patient and the remainder of the headgear drapes or hangs from the grasped portion.
• a headgear or part of a headgear includes two or more lapped panels
• an edge of one or more of the panels may extend past an adjacent edge of one or more of the other lapped panels.
• An example of this was previously described in relation to Figure 13, where the first panel 1 beyond the second panel 2 is unlapped and unsupported by the second panel 2.
• this configuration may allow contact pressure on the patient's head to gradually reduce from the edge of the lapped parts of first panel 1 and second panel 1 to the distal most unlapped part of the first panel 1. This may provide an edge softening effect for a patient when the headgear is worn.
• Figure 34 illustrates a headgear 10 with such edge softening properties along at least part of an upper edge of the rear portion.
• the rear portion 100 of the headgear 10 includes a first panel 1 and second panel 2.
• a portion 1 a first panel 1 at the rear portion 100 extends past the upper edge of the second panel 2.
• the portion 1 a of the first panel 1 not lapped by the second panel 2.
• the first panel 1 defines an upper edge 401 of the rear portion 100 of the headgear around at least part of the rear of the patient's head.
• a top strap 200 is attached to the rear portion 100, and the portion 1 a of the first panel 1 also extends beyond the upper edge of the top strap 200.
• the overhanging portion 1 a of the first panel 1 may provide an edge softening effect for a patient when the headgear is worn.
• the first panel 1 including the overhanging portion 1 a is provided to be inside of the top strap 200 relative to the patient's head. As such, the overhanging portion 1 a will roll away from the patient's head and preferably over the top strap 200 when the headgear is worn.
• a panel which has an unlapped portion peripheral portion may be at least one of thinner, softer, and less dense than the headgear panel or part which it overlies, for example in the case of Figure 34, the top strap 200.
• this panel configuration may be utilised at the lower periphery of the rear portion 100, and/or at the ear loops 320.
• the panels of the headgear may be configured to give a particular overall shape or structure to the headgear, which it may have when it is not being worn.
• Such shapes or structures may be important for signalling to a patient or person who will apply the headgear to a patient the nature of the various parts, and their intended orientations for donning.
• the headgear at rest presents an opening between the straps of each side within which the patient's head may be received.
• the headgear at rest presents the side straps as distinct members, projecting away from the remainder of the headgear and potentially also individually of each other, to allow easy identification and grasping of each strap by the patient so that they may be connected to the interface.
• This shape and structure may for instance be demonstrated when the headgear 10 is held by a patient, or particularly when a portion of the headgear is grasped by the patient and the remainder of the headgear drapes or hangs from the grasped portion.
• Figure 35 illustrates a headgear 10 that is configured to display certain shape and form when not worn.
• the headgear 10 may have a top strap 200 which has sufficient stiffness that it at rest retains an at least partially circular form. This is shown in the example of Figure 35, where the remainder of the top strap 200 draping from the patient's hand demonstrates a substantially circular form.
• the straps 300 can project away from the remainder of the headgear 10, and also discretely of each other.
• the panel or panels which comprise the straps 300 may be provided of a material of sufficient stiffness so as to drape with a sufficiently low amount of curvature over their length.
• either or both of the rear portion 100 and/or top strap 200 to which the straps 300 attach may bias the straps to fall outwardly, away from each other and away from the remainder of the headgear 10.
• the straps 300 and/or the panels of the remainder of the headgear to which they lap may be provided with a natural curl or curve to them.
• a base panel may be lapped with a more peripheral stretch panel which is pre-stretched when fused to the base panel. This may induce a natural curvature in the fused panels, to provide a desired natural shape and/or divergence away from each other of the straps 300.
• the headgear may be configured to visually or by tactile cues signal these things to a patient.
• the top strap and rear portion of the headgear may be provided of one or predominantly one colour.
• one or more of the straps 300 may be provided having a different colour and/or texture than that of the top strap 200.
• the upper side straps 301 and 303 may be provided having a different colour and/or texture than that of the lower side straps 302 and 304. Any such structural, visual, and/or tactile cues which may be built into the headgear may additionally or alternatively be utilised to aid a patient in differentiating between an internal surface 5 and an external surface 4 of the headgear 10.
• some or all of the panels which comprise the inner surface may be provided having a different colour or different colours than some or all of the panels which comprise the external surface 4 of the headgear.
• some or all of the panels which comprise the internal surface 5 of the headgear may have a different texture than some or all of the panels defining the external surface 4.
• the texture of the inner surface 5 may be in part or whole softer than the external surface 4, to aid in signalling to the patient that this part should be in proximity to their head as well as to provide enhanced comfort when worn.
• the location of a join 572 between the rear portion 100, top strap 200, and side straps 300 may be configured to sit above the ear of the patient.
• the side straps 300 of a headgear 10 may include one or more strap panels which are fused together.
• the ends of the side straps of the headgear may pass through a fixture on the respiratory interface and fold back onto and fasten to themselves.
• a two-part fastener system provided on the side strap, such as a hook-and-loop fastener.
• Figure 37A shows an index panel 335 which is to be fused onto a base panel 310 to form a side strap.
• the index panel 335 includes at least a series of step-like formations 337 which extend at least partially between the two sides of the index panel 335.
• the index panel 335 may comprise a material which is relatively stronger, stiffen denser, and/or harder than the underlying base panel 310 to which it is to be fused.
• Figure 37B illustrates the index panel 335 of Figure 37A fused to a base panel 310.
• the index panel 335 may come in contact with a fixture of the respiratory interface as the strap end is passed through it and pulled back towards the rear portion 100 of the headgear.
• the step formations 337 of the index panel 335 may provide tactile feedback to the patient as the straps are tightened on the respiratory interface.
• a further function of such an index panel 335 which is of a relatively stronger, stiffen denser, and/or harder material than the base panel 310 may be to provide wear resistance to the strap 301 as it engages with and passes over the fixture of the respiratory interface.
• a strap may include an index panel 335 without the defined cut-outs 336 to provide tactile feedback but may instead have an index panel 335 without cut-outs.
• Figure 38 illustrates a further configuration of a side strap 301 which includes a base panel 310 and an index panel 335 fused to it.
• a distal portion of the strap 301 has within cut-outs of the index panel 335 a first part 331 of a fastener system which corresponds with second part 332 of a fastener system.
• the second part 332 may be provided by the material of the base panel 310 itself, or by another material fused thereto.
• the index panel 335 may be provided just as the step formations 337.
• the index panel 335 may instead comprise a plurality of step formations 337 without any linking material to define a single unitary panel.
• the step formations 337 may present a raised surface above the surface of an underlying strap panel, such that the step formations provide resistance to movement of the strap relative to the interface.
• the spacing of the step formations may provide for an indication of indexing of each strap by a patient as they adjust the tension on the headgear straps.
• the step formations 337 may be of a different and potentially harder or denser material than that of the underlying strap panel.
• the strap-end feature 350 includes a first tab panel 351 which is at least partially lapped to the strap panel 310.
• the first tab panel 351 has a greater surface smoothness than that of the strap panel 310, and thus may be able to be distinguished from it by touch.
• first tab panel 351 On top of the first tab panel 351 is a first part 331 of a hook and loop fastener.
• the outer surface of the strap panel 310 may form the second part 332 of the hook and loop fastener, to engage the strap end with the strap when the strap end is folded back onto itself.
• the strap panel 310 comprises the second half 332 of the hook and loop fastener.
• the strap panel 310 may be of an unbroken loop material, and loops presented at the surface of the strap panel 310 may be utilised as the loops of the hook and loop fastener.
• the strap panel 310 may be singly lapped by the first tab panel 351 , or it may be lapped on its other major face by a corresponding second tab panel 352, as is illustrated in the side view of Figure 39B.
• first and/or second tab panel 351 and 352 may provide a desired degree of ability to differentiate between the strap end and the remainder of the strap
• adhesive may be utilised to enhance this differentiation.
• the adhesive may provide the strap end feature 350 with an increased stiffness relative to the strap panel 310. This difference in stiffness may act the or an additional physical cue to the patient as to the presence of the strap end.
• the first and second tab panels 351 and 352 may be fully lapped against the strap panel 310 to provide a three-panel layup, such as is shown at the first lapped region 21 of Figure 39B.
• tab panels 351 and 352 may extend distally of the end of the strap panel 310, as is seen in Figure 39B, to form a second lapped region 22.
• the difference in thickness between the first lapped region 21 and second lapped region 22 may provide a further tactile cue for patient as to the location of the end of a strap.
• tab panels 351 and 352 comprise a second lapped region 22 at which they only singly lap each other, rather than lap either sides of the strap panel 310
• an additional amount, or different type, of adhesive may be utilised at the second lapped region 22. This may provide the second lapped region 22 with an increased stiffness relative to that of either the first lapped region 21 or the strap panel 310 by itself and may be another potential form of cue to a patient that they are grasping the tab ends.
• Figure 41 is a view of the upper portions of two different configurations 10a and 10b of a headgear overlaid on each other.
• the two headgear each have a different configuration of their top straps 200.
• the first configuration 10a has top straps 200a and the second configuration 10b has top straps 200b.
• the top straps 200b are oriented so they project less laterally outwards than do the top straps 200a, and instead extend primarily upwards.
• the top straps 200a are oriented so that they are substantially continuous extensions of the adjacent parts of the rear portion 100.
• top straps 200a extend laterally outwards at angles of approximately 35 degrees to horizontal.
• the second configuration with the top straps 200b project at a steeper angle to the horizontal of approximately 70 degrees to the horizontal.
• the angle of the top straps 200 of a headgear relative to a lateral axis of the headgear may influence where the top straps are located, in use, on the head of the patient. In some configurations it may be desirable for the top straps to pass, in use, vertically and laterally across the patient's head, with minimal or no proximal or distal displacement between the bases and ends of the top straps.
• top straps 200b of Figure 41 will cross the patient's head further forwards than would the more shallowly oriented top straps 200a.
• the manufacture of a headgear according to the disclosure may involve the fusing of part or all of the headgear. While various discrete fusing processes are elsewhere described herein, such as with the welding press of Figures 9A and 9B, fusing may additionally or alternatively be provided as a continuous process.
• Figure 42 illustrates a continuous welding operation where two rollers 510 are used to continuously weld two panels 511 and 512 together.
• Such a process may be desirable for increasing a speed of manufacture and may be particularly suited to continuous shapes such as welding lengths of panels which can be subsequently cut into sections for use as headgear straps.
• a continuous welding process may also be used to form a folded edge or edges of a headgear, such as is subsequently described in further detail for example in relation Figures 63-67.
• An example of a continuous fusing operation to form a headgear portion with folded edges is illustrated in Figure 42, where the rollers 510 are used to continuously fuse the first panel 511 and second panel 512 together, along the edges of the first panel 511 each of which are folded back onto the second panel 512.
• a continuous welding process may be applied to a panel or panels of a continuous width, the width of the panels may vary.
• Figure 42 illustrates a continuous welding process performed in a plane
• a continuous welding operation may be performed in other configurations such as where one or more panels are concentrically wound, and the helical joins are welded.
• An example of this is illustrated in Figure 43, where a panel 511 is wrapped into a tube shape and rollers 510 weld at least the overlapping portions to fuse them together and hold the panel 511 in its tube shape.
• a headgear according to the disclosure may be fused using one or more different fusing methods.
• fusing may be provided by one or both of discrete and continuous processes.
• Fusing may be applied using only one type of fusing process, such as a high frequency welding, or it multiple different processes such as both a high frequency welding and a direct thermal welding may be applied to the same or different parts of the headgear.
• Continuous welding processes may also be used to define fused and non-fused zones of the panels between the rollers, or to provide varying degrees of fusing, by using debossed regions of welding roller, in a similar configuration as described in relation to the die of Figure 20.
• Figure 44 is an example of a continuous welding process where two rollers 510 each include a pattern of debossed regions 513, such that the panel 511 when welded are provided with a corresponding pattern of non-fused zones 514.
• a panel or panels which are to be fused may be pre-stretched before they are fused. Pre-stretching in combination with fusing may be used to cause a planar panel to assume a 3D shape. For example, a panel may be stretched then only one part of it fused. When the tension is released, the fused portion may recover less extension than the non-fused portions. This may urge the panel to assume a 3D shape.
• Pre-stretching may be utilised in either discrete or continuous fusing processes.
• Figure 45 illustrates a continuous welding process with two rollers 510 which each act as a welding die to weld one or more panels 511 , where the panels are pre-stretched by sets of secondary rollers 515.
• a pre-stretched panel or set of panels may be lapped with another panel or set of panels which are not pre-stretched, and the lapped panels may then be welded together.
• the pre-stretching at one side of the set of lapped panels may be utilised to distort the panels into a desired 3D shape.
• pockets or voids may be formed between two panels which are to be welded together.
• Such pockets or voids may be formed by selectively non-fusing the lapped region where the void is desired.
• one or more inserts 520 may be used in forming the pocket or void.
• Figure 46-1 A illustrates two inserts 520 which are provided on top of a first panel 511.
• the inserts 520 shown have a rectangular cuboid shape, but it will be appreciated that they may be any desired shape as needed to impart the desired shape to the pocket or void.
• the second panel may optionally be stretched over the inserts 520 before the panels are fused.
• the non-fused sides 521 may subsequently be fused or otherwise closed, if required, to close the pockets and form them into closed internal voids within the panels.
• a fusing is applied across the inserts 520 they may be made of a non-fusible material.
• they may not include a dipolar material.
• they may have a melting point higher than the welding temperature.
• Figure 46-2 shows a first panel 1 which is partially lapped by a second panel 2.
• the lapped region 21 has been fused leave a series of voids 530 inside the lapped region 21 where the first panel 1 and second panel 2 are not fused together.
• Figure 46-3 shows another configuration where a first panel 1 and second panel 2 have been fused together along two opposite sides to leave a continuous pocket 530 running the length of the two lapped panels.
• the fused panels of the headgear may be used to define air conduits.
• An example of such a configuration is shown in Figure 47A, where a 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 connects to a patient interface 600. External conduits 601 and 602 may then attach to more rearward portions of the headgear at the rear of each of the straps 301 and 302 as seen in Figure 47A.
• the air conduits of the headgear may extend into the rear portion or top strap of the headgear, and the external conduit or conduits may attach at one or more locations on the rear portion or top strap of the headgear.
• Air conduits may be formed in the headgear by selectively leaving portions of the headgear unfused.
• Figure 47B illustrates a cross-sectional view through the line A-A of Figure 47A.
• a first panel 511 and second panel 512 have been fused together along their edges 821 and 822, but the central portions have been left unfused to define the air conduit 522.
• the air conduits may be formed using inserts such as the inserts 520 described in relation to Figures 46-1 A and 46-1 B.
• a pocket in a non-fused zone of the headgear may be accessible through a non- fused periphery of the lapped panels, as illustrated in Figure 46B.
• a pocket may also be accessible through a cut-out of one of the lapped panels, where the periphery of the lapped panels are otherwise fully fused together.
• Pockets of the headgear may be used to receive and hold inserts, such as stiffening inserts.
• Pockets may additionally be utilised in the manufacture of the headgear, where it is assembled in multiple steps.
• Figures 48A-D are steps in a process for attaching a strap to the remainder of the headgear by inserting the strap into a pocket of the headgear.
• Figure 48A illustrates part of a rear portion 100 of a headgear 10 that includes a strap connection portion 120.
• the rear portion 100 has a first panel 1 and a second panel 2 partially lapping the first panel 1.
• the second panel 2 includes a cut-out 530.
• the first panel 1 is visible through the cut-out 530 of the second panel 2.
• the lapped first and second panels are then subsequently welded to each other about their periphery, as illustrated by the fused zone 41 of Figure 48B.
• the fusing about the periphery of forms a pocket 531 between the first panel and second panel, which is accessible through the cut-out 530.
• the strap end may be of the same size as the remainder of the strap, or, as illustrated in Figure 48C, the strap end can be of a reduced size.
• Figure 48D illustrates the arrangement after the parts have been fused across part of the pocket, defining the fused zone 42.
• Assembling a strap to the other panels of the headgear by insertion of one part into a pocket of the other may limit the potential for misalignment of the parts during assembly.
• the end portion of the strap 300 is sized to be received through the cut-out 530.
• Using a pocket to provide such physical constraints may simplify manufacture compared to other methods, such as joining a strap or other panel by sandwiching it between the loose ends of two other panels.
• a strap and rear portion could be joined as illustrated in Figures 48A-D, but without a cut-out 530 of the second panel 2 by leaving the strap- adjacent perimeter portion of the first panel 1 and second panel 2 unwelded in the second step.
• the strap 300 can then be inserted into the pocket 531 through the open perimeter, then the components welded together.
• selective fusing of different regions of a panel or multiple lapped panels may be employed to provide a desired characteristic to a headgear or part of a headgear.
• These characteristics may include texture, thickness, stretch properties, or surface properties such as UBL properties.
• Such selective fusing may be carried out by regions, where entire parts of the headgear may be fused, and others left unfused.
• the entire lapped region 21 may be fused, while the entire unlapped region 32 is left unfused.
• the perimeter of a lapped region or part thereof may be fused, with the non- lapped region and internal portions of the lapped region left unfused.
• Selective fusing may additionally or alternatively be carried out to provide areas of patterns of fused or non-fused area, such as have been described in relation to Figures 21 and 19, respectively.
• a headgear may at one or more locations satisfy the straight-line test, such that along a straight line drawn between two edges of the headgear, and more particularly between two edges of a lapped region of the headgear, there is more welded length than there is non-welded length.
• Figure 14 illustrates a rear portion 100 of a headgear which satisfies the straight-line condition along any straight line drawn between two edges of the lapped region 21.
• the straight-line test may be satisfied in other configurations where a lapped region is not fully fused.
• the size and spacing of the fused zones 53 may be arranged such that along one or more lines drawn between locations along the upper and lower edges of the lapped region of the first and second panels the straight- lien condition may be satisfied.
• Figure 49A is a view of an example panel 1
• Figures 49B-D show examples of different arrangements or patterns of fusing that may be provided to a panel or panels of the size of the example panel 1.
• Figure 49B illustrates an array of spaced circular fused zones 41 , within a surrounding area which is unfused 31.
• Figure 49C illustrates the same array of fused zones 41 as in Figure 49B, but where the fused zones are smaller and denser than the configuration of Figure 49B.
• Figures 49B and 49C may reduce the stretch of a panel which is fused in this manner. Flowever, the stretch properties in each of the direction of the arrows 808 and 809 in Figures 49B and 49C will be altered to the same degree, owing to the symmetrical arrangement of the fused zones in each direction.
• Figure 49D shows another pattern in which fusing may be applied, where the density of fused area decreases in rows along the panel.
• Such a configuration may provide for uniform stretch characteristics across the panel in the direction of the arrows 808 when the panel is stretched in the direction of the arrows 809, but non-uniform stretch characteristics in the direction of the arrows 809 when the panel is stretched in the direction of the arrows 808.
• the degree of stretchability will increase towards the lower part of the panel as the density of fused area along the direction of stretching decreases.
• the directional stretch properties of a single panel, or a composite of panels may be locally controlled. This may allow stretch to be provided in only areas where it is desired, in a direction that it is desired, and to the degree it is desired.
• the properties of a panel or area of lapped panels may be altered without the addition of other materials or fixtures. This may allow a headgear of highly customised and localised properties to be manufactured from a single panel of unitary properties, or lapped combinations of multiple panels, each of unitary properties.
• Figure 50 illustrates a strap 300 of a headgear.
• the strap has a fused zone 41 which defines a bifurcated region towards where the strap splits into two parts 300a and 300b.
• the bifurcated nature of the fused zone 41 will allow the strap parts 300a and 300b to open away from each other in the direction of the arrows 811 but the contiguous fused zone from the split of the strap towards its end 300c along the direction of the arrows 812 will resist or prevent stretching in that direction.
• Figure 51 illustrates another similar configuration, but where the strap 300 is fused to define a first fused zone 41 towards the strap end 300c and then a decreasing amount of fused area towards the bifurcation of the strap and along each part 300a and 300b.
• This configuration will provide similar functionality as described in relation to Figure 50, but the strap will have an increased amount of stretch in the direction of the arrows 812 at the region proximate to the bifurcation due to the non-contiguous nature of the fused zone 42 in that region along the direction of the arrows 812.
• Figure 52 shows a rear portion 100 of a headgear 10 and proximate parts of two straps 301 and 302.
• the rear portion 100 and straps 301 and 302 may be formed from a single panel or combination of panels.
• the rear portion 100 and straps 301 and 302 have been fused to define fused zones 41 and 42 in which the straps are fused along their length and fingers of fused area extend from each strap 301 and 302 into the rear portion.
• the size of each fused finger tapers towards its point.
• Such a configuration may progressively limit stretch of the rear portion 100 towards its lateral sides in the direction of the arrows 812, while allowing stretch at the middle of the rear portion.
• the fused fingers may however have a less marked effect on stretch of the rear portion in the direction of the arrows 812, as the non-fused material between the fingers will allow stretch in that direction.
• Figure 53 shows a rear portion 100 which has fused zones 41 which extend continuously from one lateral side of the band 110 to the other, and fused zones 42 which extend in continuous lines from the strap connection portions 120 to the central part of the band 110.
• Such a configuration may provide for increased stiffness and ability for load transfer along the direction of the continuous parts of the fused zones 41 and 42, but still allow for stretch in the perpendicular direction.
• the headgear may resist stretching along the lateral direction of the band more than across the height of the band 110
• Figure 54 shows another headgear 10 when worn by a patient.
• the headgear 10 has a rear portion 100 which has a fused zone 41.
• the fused zone 41 comprises continuous part towards the top of the rear portion, then three triangular parts each of which taper towards the bottom of the rear portion.
• this headgear 10 may limit lateral stretch towards the top of the rear portion, but increasingly allow stretch towards the bottom of the rear portion 100.
• Figures 55A-C illustrate a further example of how a selective fusing of a panel may provide directionally different stretch properties.
• a panel 1 has been fused to define two fused zones 41 and 42.
• the two fused zones are in mirror image "T" shapes.
• the fused zones define a continuously fused part of the panel along the first diagonal of the panel in the direction of the arrows 813 but have a gap of non-fused panel between the two fused zones 41 and 42 along the other diagonal in the direction of the arrows 814.
• each "T" shape extending in the direction of the arrows 814 may provide in-plane distortion of the panel when it is stretched in along the diagonal of the arrows 814.
• the arms of the "T" shapes that extend in the direction 813 may be bent towards each other.
• straps may be manufactured which are resistant to stretching in the direction of migration. Such a configuration may aid in preventing migration of the mask on the patient's face while maintaining stretch in other directions where it may still be desirable.
• headgear straps may be manufactured that are of reduced stretch transverse to their length, but not in a direction along their length.
• Pre-stretching of panels may be combined with fusing to create surface features of the headgear.
• FIG. 56A An example of such a configuration is illustrated in Figures 56A and 56B.
• a panel 1 is shown which has been pre-stretched in the direction of the arrows 815 before being fused to define a pattern of fused zones 41 -44. After fusing the stretch is removed, and the panel is allowed to contract in the direction of the arrows 816. As the fused parts move towards each other, they may cause bunching up of un-fused parts of the panel.
• Figure 56B where the panel has recovered in the direction of the arrows 816 and bunchings 540 of the panel have been formed.
• fusing of panels may be used to alter material properties, such as stretch properties, to change the surface properties, or create surface features such as the bunchings 540
• fusing may also be used to provide structure to a headgear. As a degree of fusing increased, the fused panel or panels may become more plasticised and more rigid. Accordingly, fusing of a panel or panels may be used to provide structure to the headgear.
• fused zones may allow for reduction in the size and bulk of the headgear.
• Structure may be provided to the headgear by fusing of a panel, or by fusing another element such as a solid piece of plastic to the panel or panels of the headgear.
• Figure 57 shows a headgear 10 retaining an interface 600 to the face of a patient 700.
• the headgear 10 has three discrete fused structures 45-47. Each of the fused structures are relatively stiffer than the surrounding headgear, and act to transfer loads between different parts of the headgear while retaining a desired shape of the headgear.
• the first fused structure 45 provides stiffness between the rear portion 100 and the top strap 200.
• the second fused structure 46 provides stiffness between the top strap 200 and the upper side strap 301.
• the third fused structure 47 provides stiffness between the rear portion 100 and the lower side strap 302.
• the first fused structure 45 may aid in preventing upwards or downwards migration of the rear portion 100 on the patient's head.
• each of the second fused structure 46 and third fused structure 47 may resist upwards or downwards movement of the straps, which will in turn prevent migration of the interface 600 up or down on the patient's face.

Landscapes

• Health & Medical Sciences (AREA)
• Heart & Thoracic Surgery (AREA)
• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Anesthesiology (AREA)
• Biomedical Technology (AREA)
• Emergency Medicine (AREA)
• Hematology (AREA)
• Pulmonology (AREA)
• Animal Behavior & Ethology (AREA)
• General Health & Medical Sciences (AREA)
• Public Health (AREA)
• Veterinary Medicine (AREA)
• Helmets And Other Head Coverings (AREA)
• Finger-Pressure Massage (AREA)

Priority Applications (6)

Applications Claiming Priority (4)

Publications (1)

Family

ID=84140311

Family Applications (1)

Country Status (6)

Cited By (2)

Citations (4)

Family Cites Families (2)

• 2022
  • 2022-05-19 WO PCT/IB2022/054656 patent/WO2022243915A1/en not_active Ceased
  • 2022-05-19 JP JP2023571269A patent/JP2024517987A/ja active Pending
  • 2022-05-19 AU AU2022276184A patent/AU2022276184A1/en active Pending
  • 2022-05-19 EP EP22804170.3A patent/EP4340917A4/en active Pending
  • 2022-05-19 CA CA3173860A patent/CA3173860A1/en active Pending
  • 2022-05-19 US US18/558,356 patent/US20240316304A1/en active Pending

Patent Citations (4)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events