Headgear for masks

• US 8,950,404 B2
• Filed: 12/10/2009
• Issued: 02/10/2015
• Est. Priority Date: 12/10/2008
• Status: Active Grant

• Current Assignee: Resmed Limited (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Formica, Justin, Barbara, Anthony Paul, Gunning, Philip John, Dravitzki, Brent
• Primary Examiner(s): Yu, Justine
• Assistant Examiner(s): REILLY, KATHRYNN M
• Application Number:
  US12/998,420
• Publication Number:
  US 20110197341A1
• Time in Patent Office: 1,888 Days
• Field of Search: 128/206.21, 128/206.24, 128/206.27, 128/206.28, 128/207.11, 128/207.13, 128/207.17, 241/0, 2/86, 2417-420, 242/4
• US Class Current: 128/207.11
• 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 layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• 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 thermoplastic elastomer fibres B32B2262/0215, thermoplastic elastomer particles B32B2264/0221, thermoplastic elastomer foam B32B2266/0292
• 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, catheter medical patches B32B2556/00
• 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 (660) 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 (620, 630) 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 headgear system for holding a respiratory mask in a position on a face of a patient to enhance a mask seal with the patient'"'"'s face, the headgear system including a plurality of straps providing a four-point arrangement for attachment with the respiratory mask, said plurality of straps comprising:

at least one upper strap configured to extend above the patient'"'"'s ears in use;

at least one lower strap configured to extend below the patient'"'"'s ears in use; and

a rear portion,

wherein at least one strap of said plurality of straps is constructed from a laminate having at least a first fabric layer and a second fabric layer, said first fabric layer being constructed and arranged to be located on a patient-contacting side in use, and said second fabric layer being constructed and arranged to be located on a non patient-contacting side in use and further wherein said first fabric layer and said second fabric layer are joined at a joint configured to be positioned away from the patient'"'"'s face when in use and wherein said at least one strap of said plurality of straps has a first rounded lateral edge when viewed in cross-section, and

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

2. The headgear system of claim 1, wherein the laminate comprises a layer of resilient material between the first fabric layer and the second fabric layer.

3. The headgear system of claim 1, wherein the laminate comprises a layer of rigid material between the first fabric layer and the second fabric layer.

4. The headgear system of claim 1, wherein the laminate comprises a layer of semi-rigid material between the first fabric and the second fabric layer.

5. The headgear system of claim 1, wherein the laminate further comprises a foam layer.

6. The headgear system of claim 5, wherein said foam layer is encapsulated between said first fabric layer and said second fabric layer.

7. The headgear system as claimed in claim 1, wherein the at least one strap of said plurality of straps includes a second rounded lateral edge, opposite said first rounded lateral edge, as seen in said cross section.

8. The headgear system of claim 1, wherein the plurality of straps further comprises a stretch portion and a portion configured not to stretch.

9. The headgear system of claim 1, wherein said plurality of straps comprises an extensible portion and an inextensible portion.

10. The headgear system of claim 1, wherein the rear portion comprises a first strap being configured to engage a back of a patient'"'"'s head in a substantially circular or oval shape, the first strap having at least a portion that is substantially inextensible.

11. The headgear system of claim 1, wherein the rear portion comprises a rear loop of straps that circumscribes the rear of the head, the rear loop being substantially inextensible along its length.

12. The headgear system of claim 1, wherein the rear portion comprises a substantially inextensible arcuate region constructed to resiliently return to a predetermined shape when not in use.

13. The headgear system of claim 1, wherein the rear portion comprises a relatively inextensible rear portion that is configured to be located at the upper half of the patient'"'"'s head while in use.

14. The headgear system of claim 1, wherein the plurality of straps is relatively extensible and the rear portion is relatively inextensible.

15. The headgear system of claim 1, wherein the rear portion is 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.

16. The headgear system of claim 1, wherein said at least one lower strap includes a hook and loop material tab for attachment to the respiratory mask.

17. The headgear system of claim 1, wherein the at least one upper strap includes a hook and loop material tab for attachment to the respiratory mask.

18. The headgear system of claim 1, wherein the plurality of straps comprises a portion that is configured to be relatively self-supporting such that the headgear system maintains a three dimensional shape when not in use.

19. The headgear system of claim 1, wherein the first fabric layer and the second fabric layer are stitched in a region to stiffen the at least one strap of said plurality of straps.

20. The headgear system of claim 1, wherein the first fabric layer and the second fabric layer are ultrasonically welded in a region to stiffen the at least one strap of said plurality of straps.

21. The headgear system of claim 1, wherein the first fabric layer and the second fabric layer are compressed in a region to stiffen the at least one strap of said plurality of straps.

22. The headgear system of claim 1, wherein the first fabric layer and the second fabric layer are thickened or treated in a region to stiffen the at least one strap of said plurality of straps.

23. The headgear system of claim 1, wherein a stiffened region provides the headgear with a 3D shape when not in use.

24. The headgear system of claim 1, wherein said plurality of straps further comprises a crown strap.

25. The headgear system of claim 24, wherein the crown strap is configured to lie flat on the crown of a patient'"'"'s head in use.

26. The headgear system of claim 1, wherein the rear portion is configured to lie flat on the rear of a patient'"'"'s head in use.

27. The headgear system of claim 1, wherein at least one of said first fabric layer and said second fabric layer having, as viewed in said cross-section, a central portion and a marginal portion on each lateral side of said central portion, the central portion projecting to a plane that is offset from a plane in which each said marginal portion projects.

28. The headgear system of claim 1, wherein each of said first fabric layer and said second fabric layer forms an exterior surface of said first rounded lateral edge.

29. A headgear system for holding a respiratory mask in a position on a face of a patient to enhance a mask seal with the patient'"'"'s face, the headgear system including a plurality of straps providing a four-point arrangement for attachment with the respiratory mask, said plurality of straps comprising:

at least one upper strap configured to extend above the patient'"'"'s ear in use, the at least one upper strap including loop material and an end with hook material, for adjustable attachment to a slot of a forehead support;

at least one lower strap configured to extend below the patient'"'"'s ear in use, the at least one lower strap including loop material and an end with hook material for adjustable attachment to a headgear clip that connects with a lower part of the mask; and

a rear strap portion having a rear loop configured and dimensioned to circumscribe the rear of the patient'"'"'s head, the at least one upper strap and the at least one lower strap being attached to the rear strap portion via stitched joins, the rear strap portion comprising a material that is relatively inextensible compared to a relatively extensible material of the at least one upper strap,

wherein at least one strap of said plurality of straps is constructed from a laminate having at least a first layer and a second layer, said first layer being constructed and arranged to be located on a patient-contacting side in use, and said second layer being constructed and arranged to be located on a non patient-contacting side in use, and further wherein each of said first layer and said second layer forms a part of at least one rounded lateral edge of the at least one strap when viewed in cross-section.

30. The headgear system of claim 29, further comprising a joint located along mutual edges of the first and second layers.

31. The headgear system of claim 30, wherein the joint is positioned at approximately a center or middle of the at least one rounded lateral edge when viewed in cross section.

32. The headgear system of claim 29, wherein the laminate comprises a layer of rigid or resilient material between the first layer and the second layer.

33. The headgear system of claim 29, wherein the laminate comprises a layer of semi-rigid material between the first and the second layer.

34. The headgear system of claim 29, wherein the laminate further comprises a foam layer.

35. The headgear system of claim 34, wherein said foam layer is encapsulated between said first layer and said second layer.

36. The headgear system of claim 29, wherein the plurality of straps further comprises a stretch portion and a portion configured not to stretch.

37. The headgear system of claim 29, wherein the rear loop comprises a first strap being configured to engage a back of a patient'"'"'s head in a substantially circular or oval shape, the at least one strap having at least a portion that is substantially inextensible.

38. The headgear system of claim 29, wherein the rear loop comprises a rear loop of straps configured to circumscribe the rear of the patient'"'"'s head, the rear loop being substantially inextensible along its length and the at least one upper strap being substantially extensible along its length.

39. The headgear system of claim 29, wherein the rear strap portion comprises a substantially inextensible arcuate region constructed to resiliently return to a predetermined shape when not in use.

40. The headgear system of claim 29, wherein the rear strap portion comprises a relatively inextensible rear portion that is configured to be located at the upper half of the patient'"'"'s head while in use.

41. The headgear system of claim 29, wherein the rear strap portion is 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.

42. The headgear system of claim 29, wherein the plurality of straps comprises a portion that is configured to be relatively self-supporting such that the headgear system maintains a three dimensional shape when not in use.

43. The headgear system of claim 29, further comprising a stiffened region that provides the headgear with a 3D shape when not in use.

44. The headgear system of claim 29, wherein said plurality of straps comprises a crown strap.

45. The headgear system of claim 44, wherein the crown strap is configured to lie flat on the crown of a patient'"'"'s head in use.

46. The headgear system of claim 29, wherein the rear strap portion is configured to lie flat on the rear of a patient'"'"'s head in use.

47. The headgear system of claim 29,

wherein the first and second layers have mutual abutting edges that define a joint positioned at approximately a center or middle of the at least one rounded lateral edge when viewed in cross section;

wherein the laminate further comprises a foam layer;

wherein said foam layer is substantively encapsulated between said first layer and said second layer;

wherein the rear strap portion comprises a rear loop of straps dimensioned to circumscribe the rear of the head, the rear loop being substantially inextensible along its length;

wherein the rear strap portion comprises an arcuate region constructed to resiliently return to a predetermined 3D shape when not in use; and

wherein the relatively inextensible material of the rear strap portions is configured to be located at an upper half of the patient'"'"'s head while in use.

48. A headgear system for holding a respiratory mask in a position on a face of a patient to enhance a mask seal with the patient'"'"'s face, the headgear system including a plurality of straps providing a four-point arrangement for attachment with the respiratory mask, said plurality of straps comprising:

a pair of upper straps each configured to extend above the patient'"'"'s ear in use, each said upper strap including an outwardly facing loop material layer and an end with hook material to adjustably engage the outwardly facing loop material layer, for length-adjustable attachment to a slot of a forehead support;

a pair of lower straps each configured to extend below the patient'"'"'s ear in use, each said lower strap including an outwardly facing loop material layer and an end with hook material to adjustably engage the outwardly facing loop material layer, for length-adjustable attachment to a headgear clip that connects with a lower part of the mask; and

a rear strap portion having a rear loop configured and dimensioned to circumscribe the rear of the patient'"'"'s head, each said upper strap and each said lower strap being attached to the rear strap portion via stitched joins, the rear strap portion comprising a first material with a first extensibility and each said upper or lower strap comprising a second material with a second extensibility that is different than the first extensibility of the first material,

wherein each of said upper strap and each said lower strap is constructed from at least a patient-contacting fabric material layer and a respective said outwardly facing loop material layer, each said patient-contacting fabric material layer being constructed and arranged to engage the patient'"'"'s face while in use, and further wherein mutual edges of the patient-contacting fabric material layer and said outwardly facing loop material layer form a joint positioned, as seen in cross-section, at a lateral edge of each said upper strap and each said lower strap, each said joint being spaced away from the patient'"'"'s face in use while the patient-contacting fabric material layer contacts the patient'"'"'s face in use.

49. The headgear system of claim 48, wherein each said lateral edge includes a rounded or tapered portion including a part of the patient-contacting fabric material layer and a part of the outwardly facing loop material layer.

50. The headgear system of claim 49, wherein each said joint is positioned at approximately a center or middle of said rounded or tapered portion when viewed in cross section.

51. The headgear system of claim 48, wherein each upper strap and each lower strap comprises a layer of rigid or resilient material between the patient-contacting fabric material layer and the outwardly facing loop material layer.

52. The headgear system of claim 48, further comprising a semi-rigid material layer between the patient-contacting fabric material layer and the outwardly facing loop material layer.

53. The headgear system of claim 48, further comprising a foam material layer for each said upper strap and each said lower strap.

54. The headgear system of claim 53, wherein said foam material layer is between each said patient-contacting material layer and a respective said outwardly facing loop material layer.

55. The headgear system of claim 48, wherein the plurality of straps further comprises a stretch portion and a portion configured not to stretch.

56. The headgear system of claim 48, wherein the rear loop comprises a first strap being configured to engage a back of a patient'"'"'s head in a substantially circular or oval shape, the first strap having at least a portion that is substantially inextensible.

57. The headgear system of claim 48, wherein the rear loop comprises a rear loop of straps configured to circumscribe the rear of the patient'"'"'s head, the rear loop being substantially inextensible along its length, and each said upper strap being substantially extensible along its length.

58. The headgear system of claim 48, wherein the rear strap portion comprises a substantially inextensible arcuate region constructed to resiliently return to a predetermined shape when not in use.

59. The headgear system of claim 48, wherein the rear strap portion comprises a relatively inextensible rear portion that is configured to be located at the upper half of the patient'"'"'s head while in use.

60. The headgear system of claim 48, wherein the rear strap portion is 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.

61. The headgear system of claim 48, wherein the plurality of straps comprises a portion that is configured to be relatively self-supporting such that the headgear system maintains a three dimensional shape when not in use.

62. The headgear system of claim 48, further comprising a stiffened region that provides the headgear with a 3D shape when not in use.

63. The headgear system of claim 48, wherein said plurality of straps comprises a crown strap.

64. The headgear system of claim 63, wherein the crown strap is configured to lie flat on the crown of a patient'"'"'s head in use.

65. The headgear system of claim 48, wherein the rear strap portion is configured to lie flat on the rear of a patient'"'"'s head in use.

66. The headgear system of claim 48,

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

wherein each said joint is positioned at approximately a center or middle of said rounded or tapered portion when viewed in cross section;

wherein a foam material layer is between said patient-contacting fabric material layer and said outwardly facing loop material layer;

wherein the plurality of straps further comprises a stretch portion and a portion configured not to stretch;

wherein the rear loop comprises a rear loop of straps configured to circumscribe the rear of the patient'"'"'s head, the rear loop being substantially inextensible along its length and each said upper strap being substantially extensible along its length;

wherein the rear strap portion comprises a substantially inextensible arcuate region constructed to resiliently return to a predetermined shape when not in use;

wherein the rear strap portion is configured to be located at the upper half of the patient'"'"'s head while in use;

wherein the rear strap portion is 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, in use,

wherein the plurality of straps comprises a portion that is configured to be relatively self-supporting such that the headgear system maintains a three dimensional shape when not in use;

wherein said plurality of straps comprises a crown strap;

wherein the crown strap is configured to lie flat on the crown of a patient'"'"'s head in use; and

wherein the rear strap portion is configured to lie flat on the rear of a patient'"'"'s head in use.