A machine for manufacturing a mask includes a plurality of carriers mounted to a belt so as and having a plurality of molding cavity inserts. A feed station supplies material from a roll so as to form a sheet of material on to the carriers. A shell forming station is configured to press a molding core inserts into the molding cavity inserts so as to form a shape of the mask. A welding station generates a predetermined ultrasonic vibration at a predetermined frequency and a predetermined amplitude so as to weld the sheet of material. A cutting station cuts out the mask from the sheet of material. A mask grabbing apparatus is configured to grab the mask and position the mask for retrieval.

Respiratory masks made of thermoformed EVA foam are provided. A mask can include a seal that contacts a user's face in use and a housing permanently joined to the seal. Both the seal and housing can be made of EVA foam. The seal and housing can be made of EVA foam having different densities. The mask can further include a frame removably or permanently coupled the housing. Headgear can be coupled to the frame and can couple the mask to the user's face in use.

A respiratory protection composite facepiece is disclosed and includes a polymeric rigid facepiece body portion having a first surface and a second surface and a silicone sealing facepiece element chemically bonded at least one of the first surface or the second surface. The first and second surfaces can be opposing major surfaces. A second silicone element is chemically bonded to at least one of the first surface or the second surface. Methods of making the same are also disclosed.

A face shield, patient interface and methods of use thereof are described for improved respiratory therapy of patients. In particular, a face shield is disclosed that acts as a seal when used with a patient interface. The face shield may be manufactured from a low melt temperature hard thermoplastic material. The face shield may be formed initially formed to match the general contours of the face, but not customised to a specific user's face. The face shield may be crosslinked to provide shape memory to the seal and to improve its handling properties and is configured to be thermoformed to a user's face. The face shield may be customised to the patient's facial features to a second customised shape.

A molded face mask for treating a user's face, the molded face mask having a rigid, inflexible polycaprolactone body molded to the user's face, the body having: i) two opposed, slightly tapered end portions; ii) a generally straight lower edge; and iii) an upper edge having a concave portion disposed approximately half-way along a length of the upper edge. A kit for providing therapeutic relief and reducing redness and bumps associated with facial shaving.

There is provided a method of manufacturing a sealing member (42). The method comprises the steps of: (a) providing a mould having a cavity, a polymer injection port and a gas inlet port (38); (b) injecting a polymer and a blowing agent through the polymer injection port (28) into the cavity of the mould; and (c) introducing gas through the gas inlet port (38) into the cavity of the mould, to form a sealing member (42). The sealing member (42) comprises an internal chamber (44) at least partially bounded by a resiliently deformable enclosing wall formed of the polymer, the enclosing wall including an external surface, the external surface having a form that is determined by the cavity of the mould.

A respiratory mask, a mould for a respiratory mask, as well as to a method for producing a respiratory mask are disclosed, in which manufacturability and usability of respiratory masks are improved. A respiratory mask is disclosed for administering a breathable gas to a patient, the respiratory mask comprising a first component formed from a flexible material and a second component formed from a material that is more rigid than the flexible material, wherein the first component is formed onto the second component by an overmoulding process.

A respiratory apparatus may employ ultrasonic welds. The ultrasonic welding may be used to join a variety of headgear, mask and accessory components. This process may enhance comfort, fit and/or performance of the joined components and/or overall mask assembly. A component may be a single layer component such as a textile or fabric, or a composite or multiple layer component such as fabric and foam composites, or outer fabric layers and inner spacer fabrics. Further, a component may be a strap, some other headgear component, a mask component, an accessory component or the like.

Interfaces for positive pressure therapy having a mask assembly, a headgear assembly and a connection port assembly are disclosed herein. The connection port assembly has a ball joint connection with the mask assembly and includes a quick release button for easily disconnecting the gases source conduit from the mask assembly. The mask assembly may include a bias flow vent that is formed separately and attached to the mask assembly. The headgear assembly encircles the rear region of the user's head and may include at least some portions that are substantially non-stretchable.

The invention entails a silicone mask with replaceable filter element, including an adjustable strap, a silicone seal ring, a mask framework, a filter element, a face shell and a protective shield. The preparation method is to directly put the adjustable strap, the silicone seal ring, the mask framework, the filter element, the face shell and the protective shield one by one in order. The present disclosure has the advantages of convenient use and easy operation. The length of the strap is adjustable, and the silicone seal ring is made of liquid silicone by molding at one time, which has the characteristics of comfortable wearing and good sealing. The filter element is an embedded structure, which is easy to replace in the process of use, and realizes the recycling of other parts of the silicone mask.