Manufactured to shape headgear and masks

• US 10,569,044 B2
• Filed: 08/21/2012
• Issued: 02/25/2020
• Est. Priority Date: 08/22/2011
• Status: Active Grant

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Inventors: Dunn, Jessica Lea, Formica, Justin John, Barbara, Anthony Paul
• Primary Examiner(s): Stanis, Timothy A
• Assistant Examiner(s): Murphy, Victoria
• Application Number:
  US14/240,065
• Publication Number:
  US 20140209098A1
• Time in Patent Office: 2,744 Days
• Field of Search: 12820122, 12820123, 12820411, 12820613, 12820627, 12820711, 12820717, 2172, 2207, 21958, 2909, 2919, 66170, 66171, 66169 R
• CPC Class Codes: A61M 16/06 Respiratory or anaesthetic masks
• CPC Class Codes: A61M 16/0633 with forehead support
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 2016/0661 with customised shape
• CPC Class Codes: A61M 2205/0216 Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking
• 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: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D04B 1/225 Elongated tubular articles of small diameter, e.g. coverings or reinforcements for cables or hoses
• CPC Class Codes: D04B 21/16 incorporating synthetic threads
• CPC Class Codes: D04B 7/32 tubular goods
• CPC Class Codes: D04B 9/44 elongated tubular articles of small diameter, e.g. coverings for cables sheathing electric cables H01B13/22
• CPC Class Codes: D10B 2403/021 Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
• CPC Class Codes: D10B 2403/0221 with at least one corrugated ply
• CPC Class Codes: D10B 2403/0312 Bulk fabric, e.g. belts
• CPC Class Codes: D10B 2501/042 Headwear

Abstract

A headgear or headgear segments are manufactured to shape thereby producing little or no waste material. Techniques such as knitting, braiding, crocheting, and 3D printing can be used produce the headgear.

Claims

1. A headgear for use in supporting a respiratory mask in position on a patient'"'"'s face for positive pressure treatment of the patient, the headgear comprising:

a fully-fashioned unitary, seamless structure formed in one piece to shape without being cut from a sheet of material, said fully-fashioned unitary, seamless structure including at least a first headgear component and being configured to facilitate support of a respiratory mask in position on a patient'"'"'s face for positive pressure treatment of the patient,

wherein the fully-fashioned unitary, seamless structure includes at least one edge, said edge being an uncut portion of the unitary seamless structure,

wherein the fully-fashioned unitary, seamless structure comprises a first yarn or thread and a second yarn or thread, the second yarn or thread having a lower melt temperature than the first yarn or thread,

wherein the second yarn or thread is melted to stiffen the second yarn or thread into a rigidizing portion of the fully-fashioned unitary, seamless structure,

wherein the at least first headgear component comprises a strap, and

wherein the fully-fashioned unitary, seamless structure comprises a 3 dimensional curvature to conform to a curvature of the patient'"'"'s head.

2. The headgear of claim 1, wherein the fully-fashioned unitary, seamless structure is fully fashioned to shape by knitting.

3. The headgear of claim 1, wherein the fully-fashioned unitary, seamless structure is fully fashioned to shape by crocheting.

4. The headgear of claim 1, wherein the at least first headgear component comprises a first headgear component and a second headgear component, the first headgear component comprising the strap and the second headgear component comprising a rear portion configured to contact the patient'"'"'s head in use.

5. The headgear of claim 1, wherein the fully-fashioned unitary, seamless structure is fully fashioned to shape by weaving.

6. The headgear of claim 1, further comprising another fully fashioned unitary, seamless structure including at least a second headgear component, the at least first and second headgear components having a substantially seamless connection to one another, the at least first and second headgear components meeting at a junction.

7. The headgear of claim 6, further comprising tuck stitches connecting the at least first and second headgear components to one another in a substantially seamless manner.

8. The headgear of claim 1, further comprising one or more connection devices for connecting the headgear to the respiratory mask.

9. The headgear of claim 8, wherein the one or more connection devices are selected from a group consisting of:

a buckle and a clip.

10. The headgear of claim 8, wherein the one or more connection devices are fully fashioned with the fully-fashioned unitary, seamless structure.

11. The headgear of claim 1, wherein the at least first headgear component further comprises:

a rear portion for engagement with the back of a patient'"'"'s head; and

a plurality of side straps for engagement with the side of the patient'"'"'s face.

12. The headgear of claim 11, wherein the rear portion comprises a crown portion for engaging with the back of a patient'"'"'s head.

13. The headgear of claim 11, wherein the side straps comprise:

a pair of upper straps configured to engage with a pair of upper engagement points on the respiratory mask; and

a pair of lower straps configured to engage with a pair of lower engagement points on the respiratory mask.

14. The headgear of claim 13, wherein the rear portion comprises a crown portion for engaging with the back of a patient'"'"'s head.

15. The headgear of claim 1, wherein the at least first headgear component comprises a tubular portion forming a hollow structure therein.

16. The headgear of claim 15, wherein the tubular portion comprises a slit for insertion of a rigid element into the hollow structure.

17. The headgear of claim 1, wherein the fully-fashioned unitary, seamless structure has selvedges.

28. A mask system for treatment of a patient for sleep disordered breathing, comprising:

a mask assembly adapted to seal with the patient'"'"'s face and deliver a supply a pressurized air to the patient'"'"'s airways; and

the headgear of claim 1, the headgear being configured to facilitate support of the mask assembly in position on the patient'"'"'s face.

18. A method of forming headgear for use in holding a respiratory mask in position on a patient'"'"'s face for positive pressure treatment of the patient, comprising:

fully-fashioning a unitary, seamless structure in one piece to shape without cutting the unitary seamless structure from a sheet of material, the fully-fashioned unitary, seamless structure comprises a first yarn or thread and a second yarn or thread, the second yarn or thread having a lower melt temperature than the first yarn or thread; and

melting the second yarn or thread to stiffen the second yarn or thread into a rigidizing portion of the fully-fashioned unitary seamless structure,

wherein said fully-fashioned unitary, seamless structure includes at least a first headgear component and is configured to facilitate support of a respiratory mask in position on a patient'"'"'s face for positive pressure treatment of the patient,

wherein the fully-fashioned unitary, seamless structure includes at least one edge, said edge being an uncut portion of the unitary seamless structure,

wherein the at least first headgear component comprises a strap, and

wherein the fully-fashioned unitary, seamless structure comprises a 3 dimensional curvature to conform to a curvature of the patient'"'"'s head.

19. The method of claim 18, wherein the step of fully-fashioning comprises knitting.

20. The method of claim 18, wherein the step of fully-fashioning comprises crocheting.

21. The method of claim 18, wherein the at least first headgear component comprises a first headgear component and a second headgear component, the first headgear component comprising the strap and the second headgear component comprising a rear portion configured to contact the patient'"'"'s head in use.

22. The method of claim 18, wherein the step of fully-fashioning comprises weaving.

23. The method of claim 18, further comprising fully-fashioning another unitary, seamless structure including at least a second headgear component, the at least first and second headgear components having a substantially seamless connection to one another, the at least first and second headgear components meeting at a junction.

24. The method of claim 18, wherein the fully-fashioned unitary, seamless structure has selvedges.

25. The method of claim 18, wherein the at least first headgear component further comprises:

a rear portion for engagement with the back of a patient'"'"'s head; and

a plurality of side straps for engagement with the side of the patient'"'"'s face.

26. The method of claim 25, wherein the side straps comprise:

a pair of upper straps configured to engage with a pair of upper engagement points on the respiratory mask; and

a pair of lower straps configured to engage with a pair of lower engagement points on the respiratory mask.

27. The method of claim 26, wherein the rear portion comprises a crown portion for engaging with the back of a patient'"'"'s head.