Headgear for masks

• US 10,369,319 B2
• Filed: 01/05/2018
• Issued: 08/06/2019
• Est. Priority Date: 12/10/2008
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Inventors: Formica, Justin John, Barbara, Anthony Paul, Dravitzki, Brent James, Gunning, Philip John
• Primary Examiner(s): Tsai, Michael J
• Application Number:
  US15/862,961
• Publication Number:
  US 20180126108A1
• Time in Patent Office: 578 Days
• CPC Class Codes: A61M 16/0633 with forehead support
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 2205/02 characterised by a particular materials
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: A62B 18/084 Means for fastening gas-masks to heads or helmets
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 15/095 comprising polyurethanes
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2250/44 Number of layers variable across the laminate
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2274/00 : Thermoplastic elastomer material
• CPC Class Codes: B32B 2307/31 : Heat sealable
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/7244 : Oxygen barrier
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2307/736 : Shrinkable
• CPC Class Codes: B32B 2307/738 : Thermoformability
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/283 : comprising polysiloxanes
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/14 : characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: B32B 7/08 : by mechanical means
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina

Abstract

A headgear for use with a mask includes a first strap being configured to engage a back of a patient'"'"'s head and extend on either side of the patient'"'"'s parietal bone behind the patient'"'"'s ears and assume, in use, a substantially circular or oval shape. At least a portion of the first strap is substantially inextensible. The headgear also includes at least one second strap configured to removably connect the first strap to the mask. The second strap may be more extensible than the first strap. At least a portion of the first strap is self-supporting such that the headgear maintains a three dimensional shape when not in use. The substantially inextensible portion of the first strap is constructed to resiliently return to a predetermined shape when not in use. The arcuate region includes a first portion that may be arranged to align substantially parallel with a top of the patient'"'"'s head and a second portion being arranged to align substantially to a rear surface of the patient'"'"'s head.

Claims

1. A respiratory mask assembly for treatment of sleep disordered breathing in a patient, comprising:

a mask;

a headgear system including a plurality of straps cooperative with the mask and permitting adjustable fit of the mask, the plurality of straps comprising;

a rear portion having a closed rear loop to engage and circumscribe a back of the patient'"'"'s head;

a first upper strap and a second upper strap each attached to the rear loop via stitching, the first upper strap attached at a first join, the second upper strap attached at a second join, a first rear loop edge of the rear loop abutting a first upper strap edge of the first upper strap at the first join, a second rear loop edge of the rear loop abutting an edge of the second upper strap at the second join;

wherein the first upper strap comprises a first upper patient-contacting fabric material layer and a first upper outwardly facing loop material layer, the second upper strap comprises a second upper patient-contacting fabric material layer and a second upper outwardly facing loop material layer;

a first lower strap and second lower strap each attached to the rear portion via stitching, the first lower strap attached at a first lower join, the second lower strap attached at a second lower join, a first rear portion edge of the rear portion abutting a first lower strap edge of the first lower strap at the first lower join, a second rear portion edge of the rear portion abutting a second lower strap edge of the second lower strap at the second lower join;

wherein the first lower strap comprises a first lower patient-contacting fabric material layer and a first lower outwardly facing loop material layer, the second lower strap comprises a second lower patient-contacting fabric material layer and a second lower outwardly facing loop material layer;

wherein the first lower strap and the second lower strap are each configured to extend below the patient'"'"'s ears in use;

wherein a first upper hook portion is located proximate a free end of the first upper strap, a second upper hook portion is located proximate a free end of the second upper strap, a first lower hook portion is located proximate a free end of the first lower strap, and a second lower hook portion is located proximate a free end of the second lower strap;

wherein the first upper strap, the second upper strap, first lower strap, and the second lower strap are length-adjustable via a hook and loop connection;

wherein the mask is secured to the patient'"'"'s head with only four points of attachment including the first upper strap, the second upper strap, the first lower strap and the second lower strap;

wherein at least a portion of the rear loop is constructed from a laminate having at least a first fabric layer and a second fabric layer, the first fabric layer being constructed and arranged to be located on a non-patient-contacting side in use and the second fabric layer being constructed and arranged as a patient-contacting layer, and further wherein the first fabric layer and the second fabric layer are joined at a first longitudinal edge joint and a second longitudinal edge joint;

wherein the first fabric layer and the second fabric layer directly contact one another along each said first longitudinal edge joint and second longitudinal edge joint;

wherein the first fabric layer is formed of a first fabric material that has different properties than a second fabric material of the second fabric layer;

wherein the laminate has a first rounded lateral edge and a second rounded lateral edge when viewed in cross section;

wherein the first longitudinal edge joint is positioned at approximately a center or middle of the first rounded lateral edge when viewed in cross section and the second longitudinal edge joint is positioned at approximately a center or middle of the second rounded lateral edge when viewed in cross section; and

wherein the first longitudinal edge joint and the second longitudinal edge joint are selected from the group consisting of;

an ultrasonic weld joint, a heat sealed joint, and a computer numerical controlled knife joint.

2. The respiratory mask assembly of claim 1, wherein the rear portion is constructed and arranged to remain relatively fixed in position on the patient'"'"'s head in use;

wherein the first upper strap has a first upper length spanning between the first join and the first upper hook portion, the second upper strap has a second upper length spanning between the second join and the second upper hook portion, and the first lower strap has a first lower length spanning between the first lower join and the first lower hook portion, the second lower strap has a second lower length spanning between the second lower join and the second lower hook portion;

wherein said first upper length is relatively more extensible than the first lower length, and the second upper length is relatively more extensible than the second lower length;

wherein the rear portion includes a base portion, a first elongated body attached to the base portion, a second elongated body attached to the base portion, and a top strap that extends between the first elongated body and the second elongated body, wherein a portion of the base portion, the first elongated body, the second elongated body, and the top strap form the rear loop;

wherein the top strap is configured to extend along the patient'"'"'s parietal bones;

wherein the top strap is elastic;

wherein the first elongated body and the second elongated body each resiliently return to a predetermined shape when not in use;

wherein the first upper strap, the second upper strap, the first lower strap, and the second lower strap are configured to removably associate the rear loop with the mask;

wherein the rear portion includes a first upper arm extending transverse from the first elongated body and a second upper arm extending transverse from the second elongated body, wherein the first upper strap removably associates the mask to the first upper arm, and the second upper strap removably associates the mask to the second upper arm; and

wherein said first lower strap and second lower strap each attach with the mask via clips.

3. The respiratory mask assembly of claim 2, wherein the rear loop is arched such that in use an upper portion of the rear loop extends along a first plane such that the upper portion lies flat on a crown of the patient'"'"'s head, and wherein a lower portion of the rear loop extends along a second plane such that the lower portion of the rear loop lies flat on a back of the patient'"'"'s head, wherein the first plane is substantially orthogonal to the second plane;

wherein the first elongated body and the second elongated body each comprise a rigidizer between the first fabric layer and the second fabric layer, wherein the rigidizer is formed of a material selected from the group consisting of;

nylon, polypropylene, polycarbonate, polystyrene, polyethylene, thermoplastic elastomer, thermoplastic urethane, silicone, and polyester;

wherein the first elongated body includes a first thickened portion, and the second elongated body includes a second thickened portion, wherein the first thickened portion assists in maintaining a shape of the first elongated body and the second thickened portion assists in maintaining a shape of the second elongated body;

wherein the rigidizer is between 0.5 mm and 5 mm thick;

wherein the rigidizer has the same width as the first fabric layer and second fabric layer;

wherein stretch characteristics are approximately equal on both sides of said first upper strap and second upper strap and said first lower strap and second lower strap;

wherein at least a portion of the rear loop is thicker than the said first upper strap and second upper strap, and said first lower strap and second lower strap;

wherein the first upper strap and the second upper strap each extend downwardly from the rear loop toward the mask;

wherein, in use, said first upper strap and second upper strap each associate with the mask at a location below the patient'"'"'s eyes;

wherein said first lower strap and second lower strap each attach to the base portion;

wherein mutual edges of the first upper patient-contacting fabric material layer and the first upper outwardly facing loop material layer form a first upper strap join positioned, as seen in cross section at a first upper lateral edge of the first upper strap;

wherein mutual edges of the second upper patient-contacting fabric material layer and the second upper outwardly facing loop material layer form a second upper strap join positioned, as seen in cross section at a second upper lateral edge of the second upper strap;

wherein mutual edges of the first lower patient-contacting fabric material layer and the first lower outwardly facing loop material layer form a first lower strap join positioned, as seen in cross section at a first lower lateral edge of the first lower strap;

wherein mutual edges of the second lower patient-contacting fabric material layer and the second lower outwardly facing loop material layer form a second lower strap join positioned, as seen in cross section at a second lower lateral edge of the second lower strap; and

wherein the first upper lateral edge, includes a first upper rounded or tapered portion including a part of the first upper patient-contacting fabric material layer and a part of the first upper outwardly facing loop material layer;

wherein the second upper lateral edge, includes a second upper rounded or tapered portion including a part of the second upper patient-contacting fabric material layer and a part of the second upper outwardly facing loop material layer;

wherein the first lower lateral edge, includes a first lower rounded or tapered portion including a part of the first lower patient-contacting fabric material layer and a part of the first lower outwardly facing loop material layer; and

wherein the second lower lateral edge, includes a second lower rounded or tapered portion including a part of the second lower patient-contacting fabric material layer and a part of the second lower outwardly facing loop material layer.

4. The respiratory mask assembly of claim 1, wherein the rear portion is constructed and arranged to remain relatively fixed in position in use;

wherein the rear loop is adapted to extend along the patient'"'"'s parietal and zygomatic bones, and the rear loop comprises a rigidizer between the first fabric layer and the second fabric layer, wherein the rigidizer is formed of a material selected from the group consisting of;

nylon, polypropylene, polycarbonate, polystyrene, polyethylene, thermoplastic elastomer, thermoplastic urethane, silicone, and polyester;

wherein the rear loop is constructed and arranged to assume a predetermined shape when not in use;

wherein rear loop comprises a self-supporting structure;

wherein the at least a portion of the rear loop is extensible up to less than 5% under forces normally encountered in use of the respiratory mask assembly, wherein the rear loop is bendable;

wherein at least one of said first upper strap and second upper strap, and said first lower strap and second lower strap is configured to removably associate the rear loop with the mask;

wherein the rear loop is arched such that in use an upper portion of the rear loop extends along a first plane such that the upper portion lies flat on a crown of the patient'"'"'s head, and wherein a lower portion of the rear loop extends along a second plane such that the lower portion of the rear loop lies flat on a back of the patient'"'"'s head, wherein the first plane is substantially orthogonal to the second plane; and

wherein the rear loop comprises a thickened portion, wherein the thickened portion assists in maintaining a shape of some or part of the headgear system.

5. The respiratory mask assembly of claim 4, wherein the rigidizer is between 0.5 mm and 5 mm thick.

6. The respiratory mask assembly of claim 1, wherein the headgear system includes at least one rigidizer constructed of rigid or semi-rigid material;

wherein the rigidizer has the same width as the first and second fabric layer;

wherein stretch characteristic are approximately equal on both sides of said first upper strap and second upper strap and said first lower strap and second lower strap;

wherein the rigidizer is located between the first fabric layer and the second fabric layer;

wherein the rigidizer is completely encapsulated by the first fabric layer and the second fabric layer;

wherein at least one of the first and second fabric layers is laminated onto foam; and

wherein at least a portion of the rear portion is thicker than said first upper strap and second upper strap and said first lower strap and second lower strap.

7. The respiratory mask assembly of claim 6, wherein the rigidizer is neither elastic nor extendible along its length.

8. The respiratory mask assembly of claim 1, wherein the rear loop includes an upper portion, wherein the upper portion extends from the first upper strap to the second upper strap, wherein the rear loop is angled at approximately 90 degrees from the first upper strap and approximately 90 degrees from the second upper strap when worn by the patient, and wherein said first lower strap and second lower strap extend at an angle from the rear portion with respect to a horizontal plane, wherein the angle is about 10-30 degrees from the horizontal plane.

9. The respiratory mask assembly of claim 8, wherein the rear loop has a variable width and an inner edge and an opposite outer edge, a first rear loop width measured from the inner edge to the first join being greater than a second rear loop width measured from the inner edge to the outer edge at a location between the first join and the first lower join.

10. The respiratory mask assembly of claim 9, wherein the inner edge of the rear loop defines an opening, the opening being substantially circular, an upper portion of the opening configured to accept the parietal bones of the patient and a lower portion of the opening configured to accept an occiput bone of the patient.

11. A respiratory mask assembly for treatment of sleep disordered breathing in a patient, comprising:

a mask;

a headgear system comprising;

a rear portion having a closed rear loop to engage and circumscribe a back of the patient'"'"'s head, the rear loop having a variable width and an inner edge and an opposite outer edge;

a first upper strap and a second upper strap each attached to the rear loop via stitching, the first upper strap attached at a first join, the second upper strap attached at a second join, a first rear loop edge of the rear loop abutting a first upper strap edge of the first upper strap at the first join, a second rear loop edge of the rear loop abutting an edge of the second upper strap at the second join;

a first lower strap and second lower strap each attached to the rear portion via stitching, the first lower strap attached at a first lower join, the second lower strap attached at a second lower join, a first rear portion edge of the rear portion abutting a first lower strap edge of the first lower strap at the first lower join, a second rear portion edge of the rear portion abutting an second lower strap edge of the second lower strap at the second lower join;

a first rear loop width measured from the inner edge to the first join being greater than a second rear loop width measured from the inner edge to the outer edge at a location between the first join and the first lower join;

wherein the first lower strap and the second lower strap are each configured to extend below the patient'"'"'s ears in use;

wherein a first upper hook portion is located proximate a free end of the first upper strap, a second upper hook portion is located proximate a free end of the second upper strap, a first lower hook portion is located proximate a free end of the first lower strap, and a second lower hook portion is located proximate a free end of the second lower strap;

wherein the first upper strap has a first upper length spanning between the first join and the first upper hook portion, the second upper strap has a second upper length spanning between the second join and the second upper hook portion, and the first lower strap has a first lower length spanning between the first lower join and the first lower hook portion, the second lower strap has a second lower length spanning between the second lower join and the second lower hook portion;

wherein said first upper length is relatively more extensible than the first lower length, and the second upper length is relatively more extensible than the second lower length;

wherein the first upper strap is constructed from a laminate having at least a first fabric layer and a second fabric layer, the first fabric layer being constructed and arranged to be located on a non-patient-contacting side in use, and further wherein the first fabric layer and the second fabric layer are joined at a first longitudinal edge joint and a second longitudinal edge joint;

wherein the first fabric layer and the second fabric layer are joined along each said first longitudinal edge joint and second longitudinal edge joint;

wherein the first longitudinal edge joint is positioned at approximately a center or middle of a first lateral edge when viewed in cross section and the second longitudinal edge joint is positioned at approximately a center or middle of a second lateral edge when viewed in cross section;

wherein the mask is secured to the patient'"'"'s head with only four points of attachment including the first upper strap, the second upper strap, the first lower strap and the second lower strap; and

wherein the first upper strap, the second upper strap, first lower strap, and the second lower strap are length-adjustable via a hook and loop connection.

12. The respiratory mask assembly according to claim 11, wherein the rear portion is constructed and arranged to remain relatively fixed in position in use;

wherein the rear portion includes a top strap configured to extend along the patient'"'"'s parietal bones;

wherein the rear portion includes a first upper arm extending transverse from the rear loop and second upper arm extending transverse from the rear loop, wherein the first upper strap removably associates a first portion of the mask to the first upper arm, and the second upper strap removably associates a second portion of the mask to the second upper arm;

wherein the rear portion includes a base portion, wherein the rear loop includes a left side portion and right side portion, wherein at the base portion, the right side portion and the left side portion of the rear loop are stitched to each other;

wherein a vertical length of the base portion of the rear portion is between 30 and 60 mm;

wherein the rear loop is arched such that in use an upper portion of the rear loop extends along a first plane such that the upper portion lies flat on a crown of the patient'"'"'s head, and wherein a lower portion of the rear loop extends along a second plane such that the lower portion of the rear loop lies flat on a back of the patient'"'"'s head, wherein the first plane is substantially orthogonal to the second plane;

wherein, in use, said first upper strap and second upper strap extend above the patient'"'"'s eyes from the rear loop to the mask;

wherein said first upper strap and second upper strap attach to a forehead support portion of the mask;

wherein said first lower strap and second lower strap are each attached to the mask via clips;

wherein a conformable material is located between said first fabric layer and second fabric layer;

wherein each said first longitudinal edge joint and second longitudinal edge joint is positioned away from a face of the patient during use; and

wherein at least the first upper strap has a first rounded lateral edge when viewed in cross section.

13. The respiratory mask assembly according to claim 12, wherein the rear portion comprises a thickened portion, wherein the thickened portion assists in maintaining a shape of some or part of the rear portion;

wherein stretch characteristics are approximately equal on both sides of said first upper strap and second upper strap, and said first lower strap and second lower strap;

wherein at least one of said first fabric layer and second fabric layer is laminated onto foam;

wherein a non-woven material is inserted between said first fabric layer and second fabric layer;

wherein the base portion includes a rigidizer, wherein the rigidizer includes stitched regions to stiffen the base portion, wherein the stitched regions compress an interior layer of the base portion, wherein the stitched regions are spaced from a base portion edge of the base portion; and

wherein said first upper strap and second upper strap each have the same width as each of said first lower strap and second lower strap.

14. The respiratory mask assembly according to claim 11, wherein the rear loop includes an upper portion, wherein the upper portion extends from the first upper strap to the second upper strap, wherein the rear loop is angled at approximately 90 degrees from the first upper strap and approximately 90 degrees from the second upper strap when worn by the patient, and wherein said first lower strap and second lower strap extend at an angle from the rear portion with respect to a horizontal plane, wherein the angle is about 10-30 degrees from the horizontal plane.

15. The respiratory mask assembly according to claim 14, wherein the inner edge of the rear loop defines an opening, the opening being substantially circular, an upper portion of the opening structured to accept the parietal bones of the patient and a lower portion of the opening structured to accept an occiput bone of the patient.

16. The respiratory mask assembly according to claim 15, wherein the rear loop includes a base portion, the rear loop being pre-configured to engage with different planes of the patient'"'"'s head, the upper portion being pre-configured to extend in a first plane to engage with a crown of the patient'"'"'s head, the base portion of the rear loop being pre-configured to extend along a second plane, wherein the first plane is substantially orthogonal to the second plane;

and wherein the base portion is adapted to cup the patient'"'"'s occiput.

17. The respiratory mask assembly according to claim 11, wherein the rear loop includes an upper portion that extends along the parietal bones of the patient'"'"'s head during use, wherein the upper portion is extensible up to less than 5% under force normally encountered in use of the respiratory mask assembly, and wherein each of said first lower strap and the second lower strap is extensible up to less than 5% under forces normally encountered in use of the respiratory mask assembly.

18. A respiratory mask assembly for treatment of sleep disordered breathing in a patient, comprising:

a mask;

a headgear system including a plurality of straps cooperative with the mask and permitting adjustable fit of the mask, the plurality of straps comprising;

a rear portion having a closed rear loop with a rear strap to engage and circumscribe a back of the patient'"'"'s head;

a first upper strap and second upper strap each attached to the rear strap via stitching, the first upper strap attached at a first join, the second upper strap attached at a second join, the first upper strap adjustably associated with to a first part of the mask, the second upper strap adjustably associated with a second part of the mask;

a first lower strap and second lower strap each attached to the rear strap via stitching, the first lower strap attached at a first lower join, the second lower strap attached at a second lower join, the first lower strap adjustably associated with a third part of the mask, the second lower strap adjustably associated with a fourth part of the mask;

wherein at least the rear strap of the rear portion is constructed from a laminate having at least a first fabric layer and a second fabric layer, the first fabric layer being constructed and arranged to be located on a non-patient-contacting side in use, and further wherein the first fabric layer and the second fabric layer are joined at a joint, and wherein at least the rear strap has a first rounded lateral edge when viewed in cross section;

wherein each said joint is positioned at approximately a center or middle of the first rounded lateral edge when viewed in cross section; and

wherein the rear strap includes a first rear strap portion and a second rear strap portion;

wherein the first rear strap portion extends continuously in one piece from a first bottom edge of the rear portion to at least beyond the first join, wherein the first rear strap terminates at the first bottom edge, the second rear strap portion of the rear strap extends continuously in one piece from a second bottom edge of the rear portion to at least beyond the second join, wherein the second rear strap portion terminates at the second bottom edge;

wherein a first strap lower edge of the first lower strap aligns with the first bottom edge of the first rear strap portion;

wherein a second strap lower edge of the second lower strap aligns with the second bottom edge of the second rear strap portion and

wherein the rear loop is arched such that in use an upper portion of the rear loop extends along a first plane such that the upper portion lies flat on a crown of the patient'"'"'s head, and wherein a lower portion of the rear loop extends along a second plane such that the lower portion of the rear loop lies flat on a back of the patient'"'"'s head, wherein the first plane is substantially orthogonal to the second plane.

19. The respiratory mask assembly of claim 18, wherein the rear portion is constructed and arranged to remain relatively fixed in position in use wherein the headgear system further comprises a rigidizer adapted to extend along the patient'"'"'s parietal bones;

wherein the rear loop is arranged to assume a predetermined shape when not in use;

wherein rear loop is a self-supporting structure;

wherein the rear strap is configured to extend along the patient'"'"'s parietal bones behind the patient'"'"'s ears,

wherein the at least a portion of the rear loop is extensible up to less than 5% under forces normally encountered in use of the respiratory mask assembly;

wherein at least one of said first upper strap and second lower strap and said first lower strap and second lower strap is configured to removably associate the rear strap to the mask;

wherein the headgear system comprises a thickened portion, wherein the thickened portion assists in maintaining a shape of some or part of the headgear system;

wherein the mask is secured with 4 point attachment by said first upper strap and second upper strap and said first lower strap and second lower strap;

wherein a first upper hook portion is located proximate a free end of the first upper strap, a second upper hook portion is located proximate a free end of the second upper strap, a first lower hook portion is located proximate a free end of the first lower strap, and a second lower hook portion is located proximate a free end of the second lower strap;

wherein the rigidizer is formed of a material selected from the group consisting of;

nylon, polypropylene, polycarbonate, polystyrene, polyethylene, thermoplastic elastomer, thermoplastic urethane, silicone, and polyester;

wherein the first fabric layer is formed of a first fabric material that has different properties than a second fabric material of the second fabric layer; and

wherein the first fabric layer and the second fabric layer directly contact one another along each said joint, wherein the joint is selected from the group consisting of;

an ultrasonic weld joint, a heat sealed joint, and a computer numerical controlled knife joint.

20. The respiratory mask assembly of claim 19,

wherein each said first upper strap and second upper strap, and each said first lower strap and second lower strap comprises a patient-contacting layer and an outwardly-facing loop material layer, the patient-contacting layer of said the first upper strap and second upper strap, and said first lower strap and second lower strap is constructed and arranged to engage the patient'"'"'s head while in use, and wherein mutual edges of the patient-contacting layer and form a strap joint positioned, as seen in cross-section, at a lateral edge of each of said first upper strap and second upper strap and said first lower strap and second lower strap;

wherein each lateral edge includes a rounded or tapered portion including a part of the patient-contacting layer and a part of the outwardly-facing loop material layer; and

wherein the patient-contacting layer is formed of a third fabric material that has different properties than a fourth fabric material that forms the outwardly-facing loop material layer.

21. The respiratory mask assembly of claim 18, wherein the headgear system includes at least one rigidizer constructed of rigid or semi-rigid material;

wherein the rigidizer has the same width as the first fabric layer and second fabric layer;

wherein stretch characteristics are approximately equal on both sides of said the first upper strap and second upper strap, and said first lower strap and second lower strap;

wherein the rigidizer is located between the first fabric layer and the second fabric layer;

wherein the rigidizer is completely encapsulated by the first fabric layer and the second fabric layer;

wherein at least one of the first fabric layer and second fabric layer is laminated onto foam; and

wherein at least a portion of the rear loop is thicker than the said first upper strap and second upper strap and said first lower strap and second lower strap.

22. The respiratory mask assembly of claim 21, wherein the rigidizer is neither elastic nor extendible along its length.

23. The respiratory mask assembly of claim 21, wherein the rigidizer is between 0.5 mm and 5 mm thick.

24. The respiratory mask assembly of claim 18, wherein said first lower strap and second lower strap extend at an angle from the rear portion with respect to a horizontal plane, wherein the angle is about 10-30 degrees from the horizontal plane.

25. The respiratory mask assembly of claim 18, wherein the upper portion extends from the first upper strap to the second upper strap, wherein the rear loop is angled at approximately 90 degrees from the first upper strap and approximately 90 degrees from the second upper strap when worn by the patient.

26. The respiratory mask assembly of claim 25, wherein the rear loop has a variable width and an inner edge and an opposite outer edge, a first rear loop width measured from the inner edge to the first join being different than a second rear loop width measured from the inner edge to the outer edge at a location between the first join and the first lower join.

27. The respiratory mask assembly of claim 18, wherein the first rear strap portion and the second rear strap portion are formed as one piece.

28. A respiratory mask assembly for treatment of sleep disordered breathing in a patient, comprising:

a mask;

a headgear comprising;

a strap that connects to the mask, wherein when worn the strap forms a rear loop that extends along a patient'"'"'s occiput of in a rear portion of the strap and the strap also extends to a front of the patient'"'"'s head;

wherein the rear loop of the strap is configured to extend along the patient'"'"'s parietal bones;

a portion of the rear loop of the strap is extensible;

wherein the strap includes a first front portion and a second front portion, the first front portion connected to the rear portion at a first join, the second front portion connects to the rear portion at a second join;

wherein each of said first front portion and second front portion removably connects the rear portion of the strap to the mask via clips;

wherein the first front portion includes a first hook portion proximate a free end of the first front portion, and the second front portion includes a second hook portion proximate a free end of the second front portion;

wherein when used the patient'"'"'s eyes and ears are unobstructed by the headgear;

wherein the rear portion is constructed and arranged to remain relatively fixed in position on the patient'"'"'s head in use;

wherein the rear portion has a different extensibility than each of said first front portion and said second front portion;

wherein the first front portion has a first length spanning between the first join and the first hook portion, the second front portion has a second length spanning between the second join and the second hook portion,

wherein the first length is extensible up to less than 5% under forces normally encountered in use of the respiratory mask assembly and the second length is extensible up to less than 5% under forces normally encountered in use of the respiratory mask assembly; and

wherein stretch characteristics are approximately equal on both sides of the rear loop.

29. The respiratory mask assembly according to claim 28, wherein the mask is a nasal mask;

wherein the mask is secured with 2 point attachment by said first front portion and second front portion;

wherein the mask is secured to the patient'"'"'s head with only two points of attachment including the first front portion and the second front portion;

wherein at least the rear portion of the strap is constructed from a laminate having at least a first fabric layer and a second fabric layer, the first fabric layer being constructed and arranged to be located on a patient-contacting side in use, and the second fabric layer being constructed and arranged to be located on a non-patient-contacting side in use, wherein the first fabric layer and the second fabric layer are joined at a first longitudinal edge joint and a second longitudinal edge joint;

wherein the first longitudinal edge joint is positioned at approximately a center or middle of a first lateral edge when viewed in cross section and the second longitudinal edge joint is positioned at approximately a center or middle of a second lateral edge when viewed in cross section; and

wherein each said first longitudinal edge joint and second longitudinal edge joint is selected from the group consisting of;

an ultrasonic weld joint, a heat sealed joint, and a computer numerical controlled knife joint.

30. The respiratory mask assembly according to claim 28, wherein the strap includes a first upper strap, a second upper strap, a first lower strap and a second lower strap;

wherein the first upper strap connects to the rear portion at a first upper join, the second upper strap connects to the rear portion at a second upper join;

wherein the first front portion comprises a portion of the first lower strap and the second front portion comprises a portion of the second lower strap;

wherein said first upper strap and second upper strap removably attach to a forehead support portion of the mask;

wherein first upper strap includes a first upper hook portion proximate a free end of the first upper strap, and the second upper strap includes a second upper hook portion proximate a free end of the second upper strap;

wherein said first upper strap and second upper strap have the same width as said first lower strap and second lower strap;

wherein the first upper strap has a first upper length spanning between the first upper join and the first upper hook portion, the second upper strap has a second upper length spanning between the second upper join and the second upper hook portion;

wherein the first upper length is relatively more extensible than the first length, and the second upper length is relatively more extensible than the second length;

wherein the mask is secured to the patient'"'"'s head with only four points of attachment including the first upper strap, the second upper strap, the first lower strap and the second lower strap;

wherein the rear loop is arched such that in use an upper portion of the rear loop extends along a first plane such that the upper portion lies flat on a crown of the patient'"'"'s head, and wherein a lower portion of the rear loop extends along a second plane such that the lower portion of the rear loop lies flat on a back of the patient'"'"'s head, wherein the first plane is substantially orthogonal to the second plane;

wherein at least the rear loop is constructed from a laminate having at least a first fabric layer and a second fabric layer, the first fabric layer being constructed and arranged to be located on a patient-contacting side in use, and the second fabric layer being constructed and arranged to be located on a non-patient-contacting side in use, wherein the first fabric layer and the second fabric layer are joined at a first longitudinal edge joint and a second longitudinal edge joint;

wherein the first longitudinal edge joint is positioned at approximately a center or middle of a first lateral edge when viewed in cross section and the second longitudinal edge joint is positioned at approximately a center or middle of a second lateral edge when viewed in cross section;

wherein each said first longitudinal edge joint and second longitudinal edge joint is selected from the group consisting of;

an ultrasonic weld joint, a heat sealed joint, and a computer numerical controlled knife joint;

wherein the rear loop is adjustable; and

wherein in use each of the first upper strap and second upper strap extends above the patient'"'"'s eyes.