MEDICAL HEADGEAR

Abstract

A medical headgear fabric that includes, at least: (i) a skin-facing fabric layer; (ii) an outermost fabric layer; and (iii) a plastic or metal layer located between the fabric layers. Preferably these layers, as well as any additional layers that may be present in the fabric are thermoformed to form a substantially unitary fabric with at least a substantially laminate structure. Preferably, the fabric also includes a foam layer located between the fabric layers. Preferably, in embodiments with a layer (iii) of plastic, the plastic layer is in the form of a nylon, plastic strip. Preferably, in embodiments with a layer (iii) of metal, the metal layer is in the form of an aluminum strip.

Claims

1-25. (canceled)

26. A headgear to support a sleep apnea face mask on a patient, comprising: a thermoformed crown section configured to extend over a portion of the patient's head, the thermoformed crown section including: a first skin-facing fabric layer configured to contact the patient's skin; a first outer fabric layer; and at least one first foam layer located between the first skin-facing fabric layer and the first outer fabric layer, wherein the first skin-facing fabric layer, the first outer fabric layer and the at least one first foam layer are thermoformed together; and at least one thermoformed strap section connected to the crown section, each thermoformed strap section including: a second skin-facing fabric layer configured to contact the user's skin; a second outer fabric layer; and at least one second foam layer located between the second skin-facing fabric layer and the second outer fabric layer, wherein the second skin-facing fabric layer, the second outer fabric layer and the at least one second foam layer are thermoformed together, and wherein the at least one thermoformed strap section is configured to be attached to a sleep apnea face mask to support the face mask on the patient's face.

27. The headgear of claim 26, wherein the thermoformed crown section forms a crown unitary laminate structure and the at least one thermoformed strap section forms a strap unitary laminate structure.

28. The headgear of claim 26, wherein the at least one first foam layer comprises two layers of foam.

29. The headgear of claim 26, wherein the at least second foam layer comprises two layers of foam.

30. The headgear of claim 26, wherein the at least one thermoformed strap section includes four thermoformed strap sections.

31. The headgear of claim 26, wherein a fastener layer is attached to an outer surface of the second outer fabric layer of each thermoformed strap section.

32. The headgear of claim 31, wherein an end portion of each thermoformed strap section includes hooks for engagement with loops to attach the face mask to the headgear.

33. The headgear of claim 32, wherein the loops are provided by the second outer fabric layer of each thermoformed strap section.

34. The headgear of claim 26, wherein at least a portion of the headgear has a variable height due to thermoforming.

35. The headgear of claim 26, wherein at least one of the first skin-facing fabric layer and the first outer fabric layer is laminated onto the at least one first foam layer.

36. The headgear of claim 26, wherein each of the first skin-facing fabric layer and the second skin-facing fabric layer comprises a soft, stretchable fabric.

37. The headgear of claim 26, wherein each of the first outer fabric layer and the second outer fabric layer comprises a soft, stretchable fabric.

38. The headgear of claim 26, further comprising a joint to connect the at least one thermoformed strap section to the thermoformed crown section.

39. The headgear of claim 26, further comprising a joint to connect the at least one thermoformed strap section to the thermoformed crown section, wherein the thermoformed crown section forms a crown unitary laminate structure, wherein the at least one thermoformed strap section forms a strap unitary laminate structure, wherein the at least second foam layer comprises two layers of foam, wherein a fastener layer is attached to an outer surface of the second outer fabric layer of each thermoformed strap section, wherein an end portion of each thermoformed strap section includes hooks for engagement with loops to attach the face mask to the headgear, and wherein the loops are provided by the second outer fabric layer of each thermoformed strap section.

40. A headgear to support a sleep apnea face mask on a patient, comprising: a thermoformed crown section configured to extend over a portion of the patient's head, the thermoformed crown section including: a first skin-facing fabric layer configured to contact the patient's skin; a first outer fabric layer; and at least one first foam layer located between the first skin-facing fabric layer and the first outer fabric layer, wherein the first skin-facing fabric layer, the first outer fabric layer and the at least one first foam layer are thermoformed together thereby forming a crown unitary laminate structure; and at least one thermoformed strap section connected to the crown section, the at least one thermoformed strap section including first and second thermoformed strap sections, wherein a first portion of the thermoformed crown section proximal the first thermoformed strap section has a width that is different from a width of a second portion of the thermoformed crown section distal to the first thermoformed strap section.

41. The headgear of claim 40, wherein each thermoformed strap section includes: a second skin-facing fabric layer configured to contact the user's skin; a second outer fabric layer; and at least one second foam layer located between the second skin-facing fabric layer and the second outer fabric layer, wherein the second skin-facing fabric layer, the second outer fabric layer and the at least one second foam layer are thermoformed together, and wherein the at least one thermoformed strap section is configured to be attached to a sleep apnea face mask to support the face mask on the patient's face.

42. The headgear of claim 41, wherein the at least second foam layer comprises two layers of foam.

43. The headgear of claim 41, wherein each of the first skin-facing fabric layer and the second skin-facing fabric layer comprises a soft, stretchable fabric.

44. The headgear of claim 41, wherein each of the first outer fabric layer and the second outer fabric layer comprises a soft, stretchable fabric.

45. The headgear of claim 40, wherein the at least one first foam layer comprising two layers of foam.

46. The headgear of claim 40, wherein the at least one thermoformed strap section forms a strap unitary laminate structure.

47. The headgear of claim 40, wherein the at least one thermoformed strap section includes four thermoformed strap sections.

48. The headgear of claim 40, wherein a fastener layer is attached to an outer surface of the second outer fabric layer of each thermoformed strap section.

49. The headgear of claim 48, wherein an end portion of each thermoformed strap section includes hooks for engagement with loops to attach the face mask to the headgear.

50. The headgear of claim 49, wherein the loops are provided by the second outer fabric layer of each thermoformed strap section.

51. The headgear of claim 40, wherein at least a portion of the headgear has a variable height due to thermoforming.

52. The headgear of claim 40, wherein at least one of the first skin-facing fabric layer and the first outer fabric layer is laminated onto the at least one first foam layer.

53. The headgear of claim 40, further comprising a joint to connect the at least one thermoformed strap section to the thermoformed crown section.

54. The headgear of claim 40, wherein the width of the first portion of the thermoformed crown section is less than the width of the second portion of the thermoformed crown section.

55. The headgear of claim 40, further comprising a joint to connect the at least one thermoformed strap section to the thermoformed crown section, wherein each thermoformed strap section includes: a second skin-facing fabric layer configured to contact the user's skin; a second outer fabric layer; and at least one second foam layer located between the second skin-facing fabric layer and the second outer fabric layer, wherein the second skin-facing fabric layer, the second outer fabric layer and the at least one second foam layer are thermoformed together, and wherein the at least one thermoformed strap section is configured to be attached to a sleep apnea face mask to support the face mask on the patient's face, wherein a fastener layer is attached to an outer surface of the second outer fabric layer of each thermoformed strap section, wherein an end portion of each thermoformed strap section includes hooks for engagement with loops to attach the face mask to the headgear, and wherein the loops are provided by the second outer fabric layer of each thermoformed strap section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:

[0030] FIG. 1 is a partial cross-sectional view of a prior art medical headgear fabric;

[0031] FIG. 2 is a partial cross-sectional view of a first embodiment of a medical headgear fabric according to the present invention;

[0032] FIG. 3 is a partial cross-sectional view of a second embodiment of a medical headgear fabric according to the present invention;

[0033] FIG. 4 is a partial cross-sectional view of a third embodiment of a medical headgear fabric according to the present invention;

[0034] FIG. 5 is a partial cross-sectional view of a second embodiment of a sleep apnea headgear according to the present invention;

[0035] FIG. 6 shows a top orthographic view of a sleep apnea headgear overall geometry corresponding to both first and second sleep apnea headgear embodiments according to the present invention;

[0036] FIG. 7 shows a perspective view of the first embodiment of the sleep apnea headgear as it is being manipulated by a person;

[0037] FIG. 8 shows a perspective view of the first embodiment of the sleep apnea headgear as it is being manipulated by a person;

[0038] FIG. 9 shows a top orthographic view of the second embodiment of the sleep apnea headgear;

[0039] FIG. 10 shows a perspective view of the second embodiment of the sleep apnea headgear as it is being manipulated by a person; and

[0040] FIG. 11 shows a perspective view of the second embodiment of the sleep apnea headgear as it is being manipulated by a person.

DETAILED DESCRIPTION OF THE INVENTION

[0041] I. Headgear Fabric Structures

[0042] As will be appreciated, embodiments of the present invention provide headgear fabric and devices fabricated of materials that exhibit comfort and flexibility to the wearer, while concurrently providing stability and integrity to the headgear device.

[0043] Embodiments of the headgear are fabricated of a variety of layers of materials. Depending on the section or part of the headgear, the layers may or may not vary. Reference is made to FIG. 2 (not to scale), which shows a medical headgear fabric 200 including: a skin-facing fabric layer 206; a foam layer 208; a layer of rigid material 210; and an outer fabric layer 212. The skin-facing fabric layer includes skin-facing surface 202 (reference numeral 201 designates the skin, scalp or other portion of the patient that this fabric is intended to face or contact). The skin facing layer may be fabricated of any soft, fabric that is comfortable to the skin. The fabric may also exhibit stretch, elasticity, and/or wicking properties. Examples include, but are not limited to a nylon-LYCRA blend, and microfiber knit fabric. The primary benefit of this layer is provide minimal friction with the person's skin. It is preferable that the knit fabric is porous and allows airflow to reduce perspiration. The skin-facing fabric may be treated with a chemical that promotes wicking, i.e., transportation of moisture, through to the next layer of the assembly.

[0044] The foam layer 208 provides cushioning and is preferably breathable, aiding in allowing moisture to move away from the skin toward the outside atmosphere by means of capillary attraction. The foam may be fabricated of a cellular, stretch-elastomer foam such as that described above for section 104, including but not limited to polyurethane foam.

[0045] The layer of rigid material 210 is any rigid material that provides integrity to the structure without the need for an external support or structure (such as rigidizers or yokes that arc typically applied to similar structures on the external surface). The material may be any plastic, composite, metal, or ceramic material having enough strength to provide integrity to the structure, but also allows for some flexibility. Examples of materials include, but are not limited to, thermoplastic and fiber reinforced thermoplastic materials. Examples of thermoplastic materials include, but are not limited to, polyamides. Examples of polyamides include, but are not limited to, nylon 6 and nylon 12.

[0046] The rigid material 210 may be smaller in dimensions (i.e., the perimeter) than the dimensions of the layers it is juxtaposed or those layers positioned over or under thereto, i.e, layers 206, 208, 212, such that it can be centered in the assembly so that its sharp edges do not extend past the edge of the assembled structure, causing irritation to the person's skin. This rigid material provides a degree of stiffness to the assembly, particularly to the strap arm sections of a headgear device, to provide proper and appropriate placement of the device on the person's face and crown, as further described below in the Headgear Geometry section

[0047] The outer fabric layer 212 includes outer surface 204 and may be a material similar to material used to fabricate layer 206 such as a nylon-LYCRA blend, or microfiber knit fabric. It may further include an attachment means such as a series of small loops that provide a vehicle for engagement with a hook material to create the force that holds the headgear in place on the person. Structure 200 is merely exemplary and may include additional layers or layers disposed in a different order than shown in FIG. 2. For example, the order of layers 208 and 210 may be reversed.

[0048] It is preferable that the layers are thermoformed or thermoset together as further described below, to provide a finished product having only one seam or edge that is located away from the skin, on the outer fabric layer 212, to reduce any opportunity for skin irritation. Although thermoforming is preferable, the embodiments herein are not limited to this fabrication process and some variations may include some or all of the adjacent layers not being laminated to each other at all. Also, in embodiments where all of the adjacent layers are laminated together to form a unitary structure, other lamination processes may be used such as flame lamination.

[0049] Fabric 200 has good straight-ahead stiffness which means that the plastic layer helps direct certain sections of the headgear (for example, strap arm sections) in a specific direction, which can help facilitate assembly of medical headgears using fabric 200 to a face mask, such as a sleep apnea headgear face mask. This can obviate the need for a large of amount of different-sized headgear in order to accommodate a larger range of patient head sizes. Although not limited to any particular section o f the headgear, it is preferable that a layered structure such as fabric 200 be used in the strap arm sections of the headgear, discussed further below under the Headgear Geometry section.

[0050] FIG. 3 (not to scale) shows a medical headgear fabric 300 including: a skin-facing fabric layer 306; a foam layer 308; a metal layer 310; and an outer fabric layer 312. The skin-facing fabric layer 306 includes skin-facing surface 302 (reference numeral 301 designates the skin, scalp or other portion of the patient that this fabric is intended to face or contact) and can be fabricated of any soft fabric as indicated above for layer 206. The foam layer 308 is preferably breathable and may be fabricated of the same material discussed above in connection with layer 208. The metal layer 310 is preferably made of aluminum, and even more preferably made of galvanized aluminum. The outer fabric layer 312 includes outer surface 304 and is preferably made of similar materials as used to fabricate layer 212 above. As stated above for fabric or structure 200, the order of layers in fabric or structure 300 may also be reversed, such as layers 308 and 310. Also additional layers may be present.

[0051] As with structure or fabric 200, it is preferable that the layers of structure or fabric 300 are thermoformed or thermoset together as further described below, to provide a finished product having only one seam or edge that is located away from the skin, on the outer fabric layer 312 or on surface 304, to reduce any opportunity for skin irritation. Although thermoforming is preferable, the embodiments herein are not limited to this fabrication process and some variations may include some or all of the adjacent layers not being laminated to each other at all. Also, in embodiments where all of the adjacent layers are laminated together to form a unitary structure, other lamination processes may be used such as flame lamination.

[0052] Fabric 300 has good moldability. The metal layer helps: (i) fewer sizes of headgears accommodate a larger range of patient head sizes; and (ii) create clearances for comfort and spacing.

[0053] FIG. 4 (not to scale) shows a medical headgear fabric 350 including: a skin-facing fabric layer 356; a foam layer 358; a metal layer 360; a rigid plastic layer 362 and an outer fabric layer 364. The skin-facing fabric layer includes skin-facing surface 352 (reference numeral 351 designates the skin, scalp or other portion of the patient that this fabric is intended to face or contact). The materials used for layers 356, 358, 360, 362 and 364 may be the same as or similar to those materials used in the fabrication of fabrics 200 and 300, where like sections can use the same or similar fabric, as discussed above.

[0054] FIG. 5 shows a partial cross section of a headgear 500 including a crown section 524 and a strap section 526. Crown section 524 includes: a first crown section layer 502; a second crown section layer 504; a third crown section layer 506; and a fourth crown section layer 508. Joint 510 connects crown section 524 to strap section 526. Strap section 526 includes a first strap arm section layer 512; a second strap arm section layer 514; a third strap arm section layer 516; a fourth strap arm section layer 518; a fifth strap arm section layer 520; and a fastener layer 522. FIG. 5 also shows where the layers are located with respect to the headgear sections 524, 526, 528 shown in FIG. 6.

[0055] First crown section and fourth crown section layers 502 and 508, respectively, are preferably made of soft, stretchy fabric, the same as or similar to those materials discussed above or fabrics/structures 200, 300 and 400. Alternatively, some or all of the fourth crown section layer 508 may be made of fastener material, such as hook and loop fastener material, in order to facilitate attachment of other components to the headgear, such as a sleep apnea face mask (not shown). Second crown section layer 504 is preferably made of relatively high density foam, such as 10 lb density foam. Third crown section layer 506 is preferably made of relatively low density foam, such as 7 lb density foam.

[0056] First strap arm section and fifth strap arm section layers 512 and 520, respectively, are preferably made of soft, stretchy fabric. Alternatively, some or all of the fifth crown section layer may be made of fastener material, such as hook and loop fastener material, in order to facilitate attachment of other components to the headgear, such as a sleep apnea face mask (not shown). Under this alternative, fastener section 528 with fastener layer 522 may no longer be needed because the fastener fabric would already be present as the fifth layer. Second and fourth strap arm section layers 514, 518, respectively, are preferably made of relatively low density foam, such as 7 lb density foam. Third strap arm section layer 516 is a rigid material such as a rigid plastic layer, as discussed above in connection with fabric 200. Alternatively, or additionally, this layer 516 could be a metal, ceramic or composite layer as discussed above in connection with fabric 300.

[0057] The thickness, strength and hardness of each of the layers discussed above, may vary depending on the size and strength needed for the particular headgear device. [0058] II. Overall Headgear Geometry

[0059] The medical headgear fabrics discussed above may be used in a wide variety of geometrically shaped headgear designs. In some preferred embodiments of the present invention, different fabrics, with different laminate structures, are used for different sections of the headgear.

[0060] FIG. 6 shows a top orthographic view of a sleep apnea headgear overall geometry common to a first embodiment 500 and a second embodiment 600 of two exemplary sleep apnea headgears according to the present invention. As shown in FIG. 6, headgear 500 includes: a crown section 524; four strap arm sections 526a,526b,526c,526d; and a fastener section 528. As shown in FIG. 6, headgear 600 includes: a crown section 624; and four strap arm sections 626a,626b,626c,626d.

[0061] The main difference between headgear 500 and headgear 600 is that headgear 500 uses fabric 300 in its strap arm sections, while headgear 600 uses fabric 200 in its strap arm sections. Although this overall geometry 500, 600 is preferred, the use of the medical device headgear fabrics according to the present invention is not necessarily limited to what is shown in FIG. 6. This headgear geometry design, including strap arms and a crown section, is sometimes be referred to as a 3D headgear because it has multiple sections, with different sections having different thicknesses.

[0062] FIGS. 7 and 8 show the versatility facilitated by the use of a metal layer in the headgear fabric 300 to provide clearance from and/or comfort to a patient's face.

[0063] FIGS. 9 to 11 show how a headgear 600 made of fabric 200 and including a rigid plastic layer can be shaped and manipulated to help bring about the advantages described herein. [0064] III. Fabric Forming Processes

[0065] Flame lamination can be used to make medical headgear fabrics according to the present invention, but it is not the preferred process. The preferred thermoforming process utilizes a polyurethane (PU) foam and two nylon/spandex blends to form a three layer composite. The PU is fed into one side of the lamination machine at the same one of the fabrics is also fed in. The top surface of the foam is melted by direct flame contact to generate a tacky condition. The melted foam and fabric is then fed through a compression roller to squeeze the two materials together forcing the melted foam into the pores of the fabric. As it cools a bond is formed. This process is then repeated to bond the other fabric. Thermoforming takes previously laminated composites and utilizes a combination of heat (not flame) and pressure to generate permanent shapes and variable height within the composite.

[0066] For multi-layered products like the medical headgears of the present invention, the final composite is typically generated by taking two separate two-layer laminate sub-assemblies, inserting the plastic between these sub-assemblies, spraying some adhesive between these layers and then thermoforming the sub-assemblies together. The heat and pressure from the thermoforming process then causes the reaction in the adhesive that parts bonds the subassemblies and inserts together. Thermoforming provides more thickness and softness to the headgear for increased patient comfort. The thermoforming process can be used to make medical headgear fabrics with a plastic layer, such as fabric 200, or fabrics with a metal layer, such as fabric 300.

[0067] The fabric and headgear described herein provide all-textile, completely soft and drapable devices that provide comfort and flexibility to the wearer while maintaining stability and control on the wearer's head. The integrity of the fabric and device is provided internally, not externally to add to the comfort of the device. There are no stitches or seams present on the skin-surface side of the fabric. Accordingly, skin irritation is reduced and/or alleviated by the fabric and device described herein.

DEFINITIONS

[0068] The following definitions are provided to facilitate claim interpretation and claim construction:

[0069] Present invention: means at least some embodiments of the present invention;

[0070] references to various feature(s) of the present invention throughout this document do not mean that all claimed embodiments or methods include the referenced feature(s).

[0071] First, second, third, etc. (ordinals): Unless otherwise noted, ordinals only serve to distinguish or identify (e.g., various members of a group); the mere use of ordinals implies neither a consecutive numerical limit nor a serial limitation.

[0072] Rigid plastic: any plastic layer at least substantially more rigid than foam.

[0073] To the extent that the definitions provided above are consistent with ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), the above definitions shall be considered supplemental in nature. To the extent that the definitions provided above are inconsistent with ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), the above definitions shall control. If the definitions provided above are broader than the ordinary, plain, and accustomed meanings in some aspect, then the above definitions shall be considered to broaden the claim accordingly.

[0074] To the extent that a patentee may act as its own lexicographer under applicable law, it is hereby further directed that all words appearing in the claims section, except for the above-defined words, shall take on their ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), and shall not be considered to be specially defined in this specification. In the situation where a word or term used in the claims has more than one alternative ordinary, plain and accustomed meaning, the broadest definition that is consistent with technological feasibility and not directly inconsistent with the specification shall control.

[0075] Unless otherwise explicitly provided in the claim language, steps in method steps or process claims need only be performed in the same time order as the order the steps are recited in the claim only to the extent that impossibility or extreme feasibility problems dictate that the recited step order (or portion of the recited step order) be used. This broad interpretation with respect to step order is to be used regardless of whether the alternative time ordering(s) of the claimed steps is particularly mentioned or discussed in this document.