A headgear for a respiratory interface on the head of a user includes a first strap, a second strap, and a junction between the ends of the first strap the second strap. The straps are constructed as a tubular knitted structure having a front side configured to be positioned toward the user and a rear side configured to be positioned away from the user. The junction is constructed as a knitted structure having a front side and a rear side. In at least a portion of the junction, the front side and the rear side are joined to one another. The junction can comprise a gusset that spaces the straps apart from one another.

A patient interface assembly includes a cushion and frame assembly with a cushion portion and a frame portion that together form a breathing chamber. The frame portion includes an anterior aperture configured to receive the flow of breathable gas. Headgear includes a back portion, a pair of upper headgear straps extending from the back portion, and a pair of lower headgear straps. The patient interface assembly also includes a shroud in the form of a contoured plate. The shroud is removably mounted on the frame portion by way of a snap-fit connection and includes a pair of lower headgear connectors. The patient interface assembly also includes a forehead support extending from the shroud and having a free end with an upper headgear connector. The forehead support has a first curvature that curves in a first direction around an axis that is offset from the patient interface assembly and extends along a length of the forehead support.

A shroud for a mask system includes a retaining portion structured to retain a frame, a pair of upper headgear connectors each including an elongated arm and a slot at the free end of the arm adapted to receive a headgear strap, and a pair of lower headgear connectors each adapted to attach to a headgear strap. The retaining portion, the upper headgear connectors, and the lower headgear connectors are integrally formed as a one piece structure.

A conduit for delivering a supply of gas under a positive pressure includes a conduit wall having a first conduit end and a second conduit end. The first conduit end is adapted to be attached to the supply of gas. The conduit wall is deformable between (a) an open condition in which the conduit wall defines a conduit passage along which the supply of gas can travel between the first conduit end to the second conduit end, and (b) a collapsed condition in which the conduit wall substantially collapses the conduit passage.

A shroud for a mask system includes a retaining portion structured to retain a frame, a pair of upper headgear connectors each including an elongated arm and a slot at the free end of the arm adapted to receive a headgear strap, and a pair of lower headgear connectors each adapted to attach to a headgear strap. The retaining portion, the upper headgear connectors, and the lower headgear connectors are integrally formed as a one piece structure.

The present specification is directed a method manufacturing a patient interface for treatment of sleep disordered breathing using air pressure by delivery of air to a patient's airway. The method includes locating a shell, a first sub section of a seal forming structure, and a first section of the seal forming structure in a tool. The first sub section includes a groove. The first section is constructed from a thermoformable material. The method further includes introducing a moudling material to the tool and overmolding the shell, the first sub section, and the first section. The moulded material forms a second sub section of the seal forming structure that connects the first sub section to the shell and fully encloses the first section within the groove.

An interface for positive pressure therapy includes a mask assembly. The mask assembly includes a mask seal that is adapted to underlie the nose. The mask seal extends up the lateral sides of the nose. The mask seal has a primary seal below the nose and a secondary seal alongside the nose. The mask seal includes a rolling hinge that permits one portion of the mask seal to deform relative to another portion of the mask seal. In one configuration, the portion of the mask seal that underlies the nose is configured to deform relative to a lower portion of the mask seal.

This invention provides a mask for an mechanical ventilator, including a first opening portion that takes in inspired air from the mechanical ventilator, a second opening portion that has an edge abutting against a skin of a user to send the inspired air to at least one of a nose and a mouth of the user, and a bellows portion that is formed on at least a part of the edge of the second opening portion, forms a space for temporarily storing the inspired air and expired air of the user between the first opening portion and the second opening: portion, and deforms following a shape of a face of the user.

A mask for use in providing a flow of a treatment gas to the airway of a user. The mask includes a frame and a conformable seal which is structured to sealingly engage about at least one of at least a portion of nose or mouth of the user. The frame includes a front face and a concave shaped rear face which faces the user when the mask is disposed on the user's face. The rear face defines a cavity which is structured to receive at least one of a portion of a nose and/or mouth of the user therein. The frame also includes a number of deformable zones, each deformable zone being structured to receive a removable insert. Each deformable zone is structured to adapt to at least one of a size or shape of the removable insert received therein.

A patient interface for respiratory therapy includes a mask seal body defining a breathing chamber and having a user-contacting surface configured to contact a face of the user and surround at least the nares of the user. The patient interface also includes a pair of facial pads, each of the facial pads configured to engage the face of a user on opposing sides of the mask seal body. The facial pads are coupled to the mask seal body. The patient interface comprises a sealing mechanism configured to urge the mask seal body toward the user's face to create or maintain sealing engagement between the user-contacting surface and the user's face. In some configurations, the sealing mechanism includes a curved bridging portion that extends between the mask seal body and each of the facial pads.