An air delivery system for providing a supply of air from a source of air at positive pressure to an interfacing structure located at the entrance to the airways of a patient includes a manifold adapted to connect with the supply of positive air pressure and at least one tube connected to the manifold and adapted to deliver the supply of air to the interfacing structure. Each tube is structured to allow movement between an open phase in which the tube allows the passage of air and a collapsed phase in which the tube is collapsed. Each tube is structured such that weight of a typical patient's head against bedding apparel is sufficient to collapse the tube from the open phase to the collapsed phase.

A patient interface includes a shell with a central opening configured to receive the pressurized flow of air, a foam cushion, and an elastomeric support portion that is attached to the shell, supports the foam cushion, and forms at least part of a chamber together with the shell and the foam cushion. The elastomeric support portion includes a side wall that forms a continuous perimeter around the chamber and a resiliently flexible lip that supports the foam cushion and extends from the side wall toward an interior of the chamber. The resiliently flexible lip has an outer perimeter that is anchored to the side wall and an unsupported inner perimeter. The foam cushion overhangs the inner perimeter of the resiliently flexible lip, and the shell is more rigid than the elastomeric support portion. In addition, the foam cushion is configured to directly contact and engage a portion of the patient's skin in use.

A mask apparatus for a respiratory treatment can permit delivery of breathable gas to a user. In one example, the mask may employ a frame and cushion to form a seal for both mouth and nose. The frame may be adapted for coupling with a respiratory treatment apparatus so as to permit communication of a pressurized gas from the respiratory treatment apparatus. The cushion, which may be foam, and a frame component may be made in an overmoulding process that moulds the frame onto a pre-formed foam cushion. Such a moulding process may form a mechanical and/or chemical bonding of the foam and mask frame component. The mask frame component may be a shell of plenum chamber, such as for both nose and mouth. Various features of the cushion may further promote sealing and comfort for the under the nose design.

A patient interface for delivery of a supply of pressurised air or breathable gas to an entrance of a patient's airways comprising: a cushion member that includes a retaining structure and a seal-forming structure permanently connected to the retaining structure; a frame member attachable to the retaining structure; and a positioning and stabilising structure attachable to the frame member.

A patient interface comprises a support structure and a seal-forming structure. The support structure is arranged to support the sealing portion and is configured to connect to the frame. The sealing portion comprises textile and is attached to the support structure along an outer perimeter of the sealing portion such that in use the sealing portion may be in tension due to reactive stress of the support structure and/or a resilient stretch characteristic of the textile such that the sealing portion exerts a force against the patient's face.

A patient interface includes a frame including a textile material and a seal-forming structure provided to the frame. The seal-forming structure includes a foam material and/or a foam and textile material configured and arranged to form a seal with the patient's nose and/or mouth.

An air delivery system for providing a supply of air from a source of air at positive pressure to an interfacing structure located at the entrance to the airways of a patient includes a manifold adapted to connect with the supply of positive air pressure and at least one tube connected to the manifold and adapted to deliver the supply of air to the interfacing structure. Each tube is structured to allow movement between an open phase in which the tube allows the passage of air and a collapsed phase in which the tube is collapsed. Each tube is structured such that weight of a typical patient's head against bedding apparel is sufficient to collapse the tube from the open phase to the collapsed phase.

A respiratory mask assembly for delivering breathable gas to a patient includes a frame having a front surface and a rear surface, opposite the front surface, and adapted in use to face the patient. The frame defines an inner wall and an outer wall extending from the rear surface, the inner and outer walls being spaced to define a channel therebetween. A cushion is removably attachable to the frame such that the cushion and frame are repeatably engagable with and disengagable from one another. The cushion includes a side wall to be inserted into the channel of the frame, the side wall having a first interlocking surface that engages a second interlocking surface provided in the channel when the cushion and frame are engaged with one another. The first and second interlocking surfaces interlock with one another to removably attach the cushion to the frame.

Disclosed is a method of forming at least a portion of a mask (4) that is structured to engage at least a portion of the face of a patient (52). The method can be generally stated as including employing at least a portion of a data set (74) that is stored on a machine-readable storage medium (72) and that is representative of the shape of at least a portion of the face in generating a configuration for an cushion element (24) of the mask. The cushion element is structured to extend from a support (20) of the mask and to have an engagement end (50) bopposite the support that corresponds with the shape of the at least portion of the face. The method can be generally stated as further including subjecting a workpiece (78) to a formation operation to cause at least a portion of the workpiece to be formed into the cushion element having the engagement end.

Headgear for use with a respiratory mask is described. The headgear comprises a continuous and substantially curved elongate member extending in use below a user's nose and at least two headgear straps capable of attachment to the ends of the elongate member. A mask attachment on the elongate member is disposed to sit below or on one of said user's nose, mouth, upper lip and an inlet to the mask. The attachment is capable of receiving the mask.