Patent Description:
Masks used for treatment of SDB such as Obstructive Sleep Apnea (OSA) are typically held on a patient's head by headgear. Headgear typically includes one or more headgear straps that are adapted to engage with the mask and hold the mask in position on the patient's face. In addition, headgear should be comfortable so that a patient can wear the mask at night while they sleep. There is a continuous need in the art for headgear that is comfortable, fits a wide range of patients, is easily manufactured, and is inexpensive.

Known methods of manufacturing headgear involve cutting headgear components <NUM> from a sheet of fabric <NUM>, as shown in <FIG>. A problem with this method is that it renders a relatively large portion of the sheet <NUM> to waste. While waste can be minimized by nesting the headgear pieces as closely as possible on the sheet <NUM>, the cutting step required in this process ensures that waste material will be produced. In manufacturing headgear in a conventional manner, several different materials and several different manufacturing processes must be used. In manufacturing headgear, considerable time and labor is required to cut the components and sub-components to an appropriate size and shape, and to stitch or bond or laminate these elements to each other. These techniques are time, labor, and process intensive, and the cutting or trimming process usually results in an undesirable amount of waste compared to the part of the material actually used, even with appropriate nesting of components.

<CIT> relates to an air delivery conduit including first and second conduit portions that cooperate to form the conduit, each conduit portion including an inner layer of a film laminate that forms an interior surface of the conduit and an outer layer of a textile that forms an exterior surface of the conduit. It is said that the tubular conduit may be formed as a knitted tube.

<CIT> relates to a respiratory mask for continuous positive airway pressure. Furthermore, an air delivery and stabilizing system is described, which comprises two tubes or inlet conduits. It is said that each tube may be constructred from knitted textiles.

An aspect of the disclosed technology relates to a fabric component for use with a mask system.

Another aspect of the disclosed technology relates to a headgear for use with a mask system.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises at least one component (e.g., strap, crown portion, other head/face contacting portions) formed of a single unitary, seamless structure.

Another aspect of the disclosed technology relates to knitting various headgear sections in a continuous manner so that there are no or very few additional manufacturing steps that would be required to sew, fuse, adhere or otherwise attach adjoining sections. As a result, the manufacturing process may have reduced steps, the amount of material waste is reduced, there would be virtually no seams in the headgear between the adjoining sections, and the headgear made of a fabric without distinctive joins or seams may be more comfortable for patients.

Another aspect of the disclosed technology relates to knitting various headgear sections in a continuous manner i.e. forming a single, unitary seamless structure having at least two regions, wherein the at least two regions extend from a junction at different angular orientations. For example, a first strap may extend in a substantially horizontal direction and a second strap may extend in a substantially vertical direction, the first strap and the second strap being formed as a single, unitary seamless structure formed in a continuous process (e.g. knitting).

Another aspect of the disclosed technology relates to knitting various headgear sections in a continuous manner i.e. forming a single, unitary seamless structure having at least two regions, wherein the at least two regions branch out or extend at different angles or in different directions to one another.

Another aspect of the disclosed technology relates to a headgear for a mask, the headgear being constructed of a textile formed from mechanically manipulated yarn.

A further aspect of the disclosed technology relates to a headgear for a mask, the headgear being constructed of a textile formed from mechanically manipulated yarn by interlooping, including knitting.

A further aspect of the disclosed technology relates to a headgear for a mask, the headgear being constructed of a textile formed from mechanically manipulated yarn by interweaving.

A further aspect of the disclosed technology relates to a headgear for a mask, the headgear being constructed of a textile formed from mechanically manipulated yarn by intertwining, including braiding and knotting.

Another aspect of the disclosed technology relates to a method of manufacturing headgear comprising forming a textile to shape (e.g., formed in one piece to shape without cutting, by mechanical manipulation of yarn including means of but not limited to interlooping, interweaving, intertwining, including for example knitting, crochet, braiding, weaving or additive manufacturing/3D printing), wherein the textile is adapted to support, in use, a mask on a patient's face.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric, the spacer fabric being formed by a first and second ground layer or structure, the first and second ground layers or structures being substantially parallel.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric, the spacer fabric being formed by a first and second ground layer or structure, the first and second ground layers or structures being substantially parallel, the first and second ground layers or structures having different stiffnesses.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric, the spacer fabric being formed by a first and second ground layer or structure, and further comprising a traversing or floating yarn or pile adapted to connect the first and second ground layers or structures.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric, wherein the spacer fabric is formed by knitting.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises a strap at least partly constructed of spacer fabric, wherein an outer surface of the headgear may be formed from, for example, about <NUM>-<NUM>, <NUM>-<NUM>, or <NUM>-<NUM> denier yarn for a pleasant hand feel.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear comprises at least a first yarn and a second yarn, the first yarn having a first stiffness and the second yarn having a second stiffness.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear is formed by flat knitting or circular knitting.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear is formed by flat knitting. The headgear may further comprise pockets, tunnels, layers and/or ribs. Furthermore, the pockets or tunnels may be reinforced with stiffer materials to add rigidity to the headgear.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear is formed by flat knitting or circular knitting. The headgear may further comprise pockets, tunnels, layers and/or ribs. The pockets or tunnels may be cushioned by filling the pockets or tunnels with padding, including floating yarn, looped yarn, foam or other cushioning material.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear is formed by flat knitting or circular knitting, further wherein the headgear has selvedges, that is, ends of the yarn are distal to the edge of the headgear to prevent unraveling or fraying.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, wherein the headgear is formed by a regular or irregular pique knit so the yarn exposed on the right side is different to the yarn exposed on the wrong side. For example, the yarn on the right side may have a pleasant visual appearance and the yarn on the wrong side may have a nice hand feel for contacting the patient's skin. Alternatively, or in addition, the yarn on the right side may have a first moisture wicking property and the wrong side may have a second moisture wicking property. For example, the yarn on the right side may have a high percentage of microfiber having a first moisture wicking property and the wrong side may have a high percentage of non-microfiber having a second moisture wicking property.

Another aspect of the disclosed technology relates to a headgear for use in supporting a respiratory mask in position on a patient's face, the headgear being constructed of a yarn, the headgear having a first region with a first density of yarn and a second region with a second density of yarn. The region with the greater density of yarn may have less extensibility, less permeability and higher stiffness.

Another aspect of the disclosed technology relates to a headgear for use in supporting a respiratory mask in position on a patient's face, the headgear being constructed of a first yarn and a second yarn, the headgear having a first region constructed of the first yarn, the first yarn having a first denier and a second region constructed of the second yarn, the second yarn having a second denier.

Another aspect of the disclosed technology relates to a headgear for use in supporting a respiratory mask in position on a patient's face, the headgear being constructed of a first yarn and a second yarn, the headgear having a first region constructed of the first yarn, the first yarn having a first twist per inch property and a second region constructed of the second yarn, the second yarn having a second twist per inch property.

Another aspect of the disclosed technology relates to a headgear for use in supporting a respiratory mask in position on a patient's face, the headgear being constructed of a yarn, the yarn comprising textured filaments. The textured filaments may improve hand feel and alter the stretch characteristics of the headgear.

Another aspect of the disclosed technology relates to a method of forming a headgear for use in supporting a respiratory mask in position on a patient's face, comprising the steps of knitting the headgear with a water soluble yarn, dissolving at least an edge of the headgear in water, and drying the headgear (thereby causing it to shrink). The shrinkage of the edge of the headgear may result in a finished edge.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising a) knitting a yarn or thread to form a headgear component (e.g., a strap) adapted to at least partially support the mask, the component being connected to an attachment member, the attachment member adapted to connect the component to the mask; and in step a), looping the yarn or thread through a connecting portion formed in the attachment member to connect the component to the attachment member.

Another aspect of the disclosed technology relates to a mask system for use in treating a patient for sleep disordered breathing comprising a mask assembly adapted to seal against the patient's face thereby forming a breathing cavity, the mask having one or more portions constructed of a first knitted fabric; and a headgear connected to the mask to at least partially support the mask on the patient's face, the headgear having one or more portions constructed of at least one of the first knitted fabric and a second knitted fabric.

Another aspect of the disclosed technology relates to a mask system for use in treating a patient for sleep disordered breathing comprising a mask assembly adapted to seal against the patient's face thereby forming a breathing cavity, the mask having one or more portions constructed of a first knitted fabric; and a headgear connected to the mask to at least partially support the mask on the patient's face, the headgear having one or more portions constructed of at least one of the first knitted fabric and a second knitted fabric. The first knitted fabric may be joined to the second knitted fabric by interlooping and preferably having a seamless connection or join, for example a tuck stitch.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a yarn or thread to form a headgear component adapted to at least partially support the mask, wherein a grain or course of the knit is altered to form a curved portion of the headgear component.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a yarn or thread to form a headgear component adapted to at least partially support the mask, wherein a grain or course of the knit is arranged to allow or disallow stretch in at least one portion of the headgear component.

Another aspect of the disclosed technology relates to headgear for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, the headgear comprising a first component at least partly constructed of spacer fabric, the spacer fabric including an inner fabric, an outer fabric and an inner spacer fiber interconnecting the outer fabric and the inner fabric, wherein the inner fabric delimits a hollow interior area.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face, comprising knitting a yarn or thread to form a headgear component adapted to at least partially support the mask, the headgear component being at least partly constructed of spacer fabric and having an inner layer formed of spacer yarns; and altering a length or density of the spacer yarns in at least one portion of the headgear component to vary an attribute of the headgear component.

Another aspect of the disclosed technology relates to a mask assembly for use in treating a patient for sleep disordered breathing comprising one or more portions constructed of spacer fabric, the spacer fabric having an inner layer formed of spacer yarns, the inner layer having at least one portion forming a vent hole, wherein the at least one portion is substantially void of spacer yarns.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a yarn or thread to form a first knitted fabric; concurrently knitting a yarn or thread to form a second knitted fabric; and at the same time, knitting the first knitted fabric to the second knitted fabric such that one of the first knitted fabric and the second knitted fabric forms an inner fabric adapted to interface with the patient.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a yarn or thread to form a headgear component adapted to at least partially support the mask; and altering a number of stitches in at least one portion of the headgear component to vary an attribute of the headgear component.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a yarn or thread to form a headgear component adapted to at least partially support the mask; and altering a thread count or stitch style in at least one portion of the headgear component to vary an attribute of the headgear component.

Another aspect of the disclosed technology relates to a headgear assembly for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, the headgear comprising a first headgear component constructed of a knitted fabric, the knitted fabric including a first yarn or thread and a second yarn or thread having a higher stiffness than the first yarn or thread, wherein the second yarn or thread is arranged to provide a rigidizing portion of the first headgear component.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and comprising providing a base headgear material to form a headgear component adapted to at least partially support the mask; and then either (but not limited to) knitting, embroidering or weaving a yarn or thread into the base headgear material, the yarn or thread having a higher stiffness than the base material, wherein the yarn or thread is arranged to provide a rigidizing portion of the headgear component.

Another aspect of the disclosed technology relates to a headgear assembly for use in supporting a respiratory mask in position on a patient's face for positive pressure treatment of the patient, the headgear comprising a first yarn, the first yarn being formed from a thermoplastic, wherein the thermoplastic yarn may be fused to create a rigidized portion of the headgear component.

Another aspect of the disclosed technology relates to a method of forming headgear for use in holding a respiratory mask in position on a patient's face and by using "additive manufacturing" or "rapid manufacture" or "3D printing" processes (these terms are able to be used interchangeably in colloquial language) to create a textile which forms at least a first headgear component adapted to at least partially support the mask.

Still another aspect of the disclosed technology relates to a method of manufacturing custom headgear for use in holding a respiratory mask in position on a patient's face and comprising acquiring data related to the shape and size of the patient's head; creating an electronic headgear model with a computing device and computer aided design program in accordance with the acquired data; and forming at least a first headgear component corresponding at least in part to the electronic headgear model.

Another aspect of the disclosed technology relates to a method of manufacturing a series of headgear for use in holding a respiratory mask in position on a patient's face and comprising knitting a first headgear or headgear component, knitting a knit release, knitting a second headgear or headgear component and separating the first headgear or headgear component from the second headgear or headgear component at the knit release.

Another aspect of the disclosed technology relates to a component (e.g., headgear, mask, tube, cushion) that may be formed via processes such as knitting, weaving, crochet or embroidery in order to include the use of one or several types of yarns with various unique properties, such as conductivity. For example, a conductive yarn or thread which is integrated into the overall form of the component might be used for conveying electricity and/or data to and from, for example, similarly integrated or add-on: sensors, heating elements, cooling elements, tensioning systems, on/off buttons, power sources, computer chips, controllers etc..

Other aspects, features, and advantages of this technology will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of this technology.

The accompanying drawings facilitate an understanding of the various embodiments of this technology. In such drawings:.

The following description is provided in relation to several examples which may share common characteristics and features. It is to be understood that one or more features of any one example may be combinable with one or more features of the other examples. In addition, any single feature or combination of features in any of the examples may constitute an additional example or examples.

The figures illustrate headgear according to examples of the disclosed technology. In the illustrated examples, headgear are adapted to be removably attached to a patient interface to hold and maintain the patient interface in a desired position on a patient's face. While headgear may be illustrated as being used with a particular type of patient interface (e.g., mask), it should be appreciated that each headgear may be adapted for use with other suitable patient interfaces. That is, the patient interfaces are merely exemplary, and each headgear embodiment may be adapted for use with any suitable patient interface, e.g., full-face mask, nasal mask, mouth mask, nozzles or puffs, nasal prongs, etc, with any suitable configuration, e.g., with or without forehead support.

Also, it should be appreciated that the headgear may be used with a new patient interface or the headgear may be retrofit to an existing patient interface.

An example of a headgear <NUM> manufactured according to an example of the disclosed technology is shown in <FIG>. The headgear includes a rear portion for example a "crown" or "halo" <NUM> and a plurality of straps <NUM> attached to the rear portion. The rear portion <NUM> is adapted to accommodate the patient's occiput and the straps <NUM> are configured to connect to upper and lower headgear attachment points (e.g. clips), as one skilled in the art will understand. It is noted that the headgear <NUM> is merely an example and that other headgear configurations may be made in accordance with the disclosed technology.

The headgear <NUM> is manufactured to shape (e.g., formed in one piece to shape otherwise known as "fully-fashioning" without the need to cut away any substantial amounts of material) thereby producing little or no waste material. Alternatively, the headgear may be divided into segments that are each manufactured to shape separately (e.g., by knitting) and then attached to one another. <FIG> demonstrates a single, unitary seamless structure having at least two regions (e.g. the rear portion <NUM> and straps <NUM>), wherein the at least two regions extend from a junction (the junction being the connection between the straps <NUM> and the rear portion <NUM>), where the straps extend at a different angular orientation to the rear portion. The rear portion and straps are formed in a continuous process (i.e. the material that makes up the component and the shape of the component are formed in a single step) - this is different to a process where a sheet of material is made and then cut to shape (this would not be considered a single step). <FIG> also shows that the straps <NUM> branch out or extend at a different angle or direction to the rear portion <NUM>, without requiring seams or additional formation steps.

In <FIG>, the rear portion <NUM> and the straps <NUM> are formed separately and subsequently connected. One skilled in the art will understand that any portions of the headgear <NUM> can be formed separately and then later connected. In the example of <FIG>, the straps <NUM> are stitched to the rear portion <NUM>; however other suitable methods such as knitting, sewing, crocheting, heat bonding with adhesive tape, gluing, welding (e.g., ultrasonic welding), etc. may be used.

A knitted component such as headgear is defined as being formed of "unitary knit construction" when constructed as a one-piece knit element that is substantially free of additional stitching or bonding processes.

As shown in <FIG>, the straps <NUM> may be formed (e.g., by warp knitting) as a continuous piece that is subsequently cut as this procedure may further increase manufacturing efficiency.

Knitting various headgear sections in a continuous manner may be advantageous as there are no or very few additional manufacturing steps that would be required to sew, fuse, adhere or otherwise attach adjoining sections. As a result, the manufacturing process may have reduced steps, the amount of material waste is reduced, there would be virtually no seams in the headgear between the adjoining sections, and the headgear made of a fabric without distinctive joins or seams may be more comfortable for patients.

A number of techniques can be used in accordance with the present technology to manufacture headgear to shape with little or no waste material. Preferably, the technique may produce a headgear that is a single, unitary, seamless structure. Techniques that may produce a single unitary seamless structure include mechanical manipulation of yarn including interlooping (such as knitting), interweaving and/or intertwining (including braiding, knotting and crocheting). An alternative technique of 3D printing may also create a headgear having a unitary, seamless structure.

A manufacturing technique in accordance with the disclosed technology preferably has one or more of the following features:.

In accordance with an example of the disclosed technology, headgear may be formed by interlooping such as knitting (e.g., threading yarn or thread to form a knitted fabric). The headgear may be formed by flat knitting or circular knitting, however other forms of knitting may also be possible. Flat knitting and circular knitting may be preferable as they are able to create a headgear with a unitary, seamless structure. Flat or circular knitting machines may be utilized to create a weft knit or a warp knit. A variety of knitting processes including circular knitting and warp- or weft- flat knitting, may be utilized to manufacture the headgear component or components. Flat knitting may have some advantages, including but not limited to (<NUM>) the ability to locate floating yarns within, for example, a headgear strap, in order to provide extra cushioning or bulk, and/or (<NUM>) the ability to include extra loops of yarns on either the upper or lower surface of the headgear strap, thus creating the effect of a soft terry cloth material, for example, or creating an unbroken loop fabric for engagement with a hook tape fastener, and/or (<NUM>) the ability to knit a 3D dimensional spacer fabric construction adjacent to double-faced knit construction within a single unified headgear construction.

Preferably, the headgear is formed primarily from multiple yarns that are mechanically manipulated through an interlooping process to produce a single unitary structure having various sections with different physical properties.

<FIG> illustrates the wale of a weft knit fabric <NUM>, or the direction that the loops of one thread join to a loop of another thread. The course <NUM>, or the direction of the loops from a single thread is shown in <FIG>. <FIG> illustrate a basic closed loop warp knit <NUM>. <FIG> illustrates an example of a warp knit tricot jersey fabric structure in which a yarn is knitted in a vertical direction in a zig-zag manner, capturing other warp yarns, with the wale running somewhat parallel to the course.

Referring to <FIG>, a warp knit <NUM>, <NUM>-<NUM> comprises the wales and courses running parallel to one another, while in a weft knit <NUM> the wales run perpendicular to the course. The headgear and masks of the disclosed technology may be formed by either warp knit or weft knit. A warp knit, for example tricot, raschel or locknit, is typically more resistant to runs, easy to machine, and may utilize multiple yarns (allowing for the use of multiple colors or yarn types). A weft knit can be formed with a single yarn; however, use of multiple yarns is also possible. The headgear of the disclosed technology may be constructed of a warp knit or a weft knit.

Knitted fabrics may have different stretchability characteristics compared to woven fabrics. Knitted fabrics are typically more flexible than woven fabrics, which may only stretch in one direction (depending on the yarn they are made from), and therefore may provide a more comfortable fit for the patient. Knitted textiles may be constructed in such a way that the fabric has a two-way stretch - i.e. a first yarn oriented in a first direction has a lower flexibility than a yarn oriented in a second direction. This arrangement may be desirable along the straps of the headgear such that the straps can stretch along their length but not across their width, or vice versa. Alternatively, the knitted textile may have a four-way stretch i.e. yarn in a first direction and a second direction and both are flexible such that application to a strap would allow stretch in both lengthwise and crosswise directions.

The example of <FIG> shows a strap <NUM> having a grain or course <NUM>, and illustrates how the direction of the grain or course affects stretch. The knitted fabric will tend to stretch more readily in the direction of the course. Therefore, headgear may be designed to stretch in certain directions and be more resistant to stretch in other directions. For example, the strap <NUM> will tend to stretch in its width direction A (from the patient's face to the back of the head) and may have limited stretch along the length of the strap. This configuration may increase stability of the headgear in the lengthwise direction while increasing fit range. The strap <NUM> may be configured to stretch in certain directions and be resistant to stretch in other directions in order to better enable the strap <NUM> to hold a mask assembly on a patient's face in a manner that enhances the seal with the patient's face.

Referring to <FIG>, a mask <NUM> is held in position on a patient's face by headgear <NUM>. The mask <NUM> includes an elbow coupling portion <NUM> adapted to connect to an elbow (not shown) for supplying pressurized air to the mask. Lower mask clips <NUM> are adapted to connect to the headgear <NUM>.

The headgear <NUM> includes upper headgear straps <NUM> and lower headgear straps <NUM> configured for connection to the mask <NUM>. An attachment member <NUM> (e.g., a lower headgear clip) may have connecting portions <NUM>(<NUM>) (. e.g., holes) for receiving the strap material (e.g., thread or yarn). For example, yarn comprising the lower headgear strap may be looped through the holes <NUM>(<NUM>) during fabrication of the strap to integrate the clip <NUM> and the strap <NUM>.

In an alternative example shown in <FIG>, a mask <NUM> and headgear <NUM> are integrally formed as one piece. The mask <NUM> is knit to include open areas which function as vent holes <NUM>. An elbow coupling portion <NUM> includes holes <NUM>(<NUM>) for receiving the yarn or thread thereby integrating the mask <NUM> and elbow coupling portion <NUM>. The mask may be made air tight by laminating or other suitable methods.

The headgear <NUM> includes crown straps <NUM>, <NUM>, top strap <NUM>, and lower headgear straps <NUM>. The knit may be pulled tight or formed loosely to adjust the fit and enhance comfort in certain areas. For example, the illustrated crown straps <NUM>, <NUM> have a looser knit which enhances breathability in the area near the top of the patient's head. In contrast, the lower headgear straps <NUM> have a tight knit which creates a more rigid strap for stabilizing the mask. The top strap <NUM> includes a thinned region <NUM> designed to avoid obstruction of the patient's vision.

Referring to <FIG>, a knitted strap <NUM> includes a top portion <NUM>, a rear portion <NUM>, and a lower portion <NUM>. The lower portion <NUM> may bifurcate or branch out at a junction to form the top portion <NUM> and the rear portion <NUM>. The angular orientation of the top portion <NUM> may be different compared to the rear portion <NUM> e.g. the top portion <NUM> may extend at about <NUM>- <NUM> degrees, or about <NUM> degrees or perpendicular to the rear portion <NUM>. The direction of the knit, or the grain or course <NUM> of the knit, may be altered to adjust the shape or stretch of the fabric in certain areas. For example, the grain or course <NUM> may be configured to curve the strap at a cheek region to avoid obstructing the patient's eyes. Further, as shown in <FIG>, the grain or course <NUM> may curve, as shown by the arrows B, to a split thereby forming the top portion <NUM> and the rear portion <NUM>. Such configurations of the top portion <NUM> and the rear portion <NUM> may stabilize the straps in position on the patient's head and thus better enable the strap <NUM> to hold a mask assembly on a patient's face in a manner that enhances the seal with the patient's face.

The strap <NUM> may support a patient interface <NUM> (e.g., a nasal mask) on the patient's face. A connector <NUM> may be used to attach the strap <NUM> to the patient interface <NUM>, and a supply tube <NUM> may deliver breathable gas to the patient's airways via the patient interface. In the illustrated example, the patient interface <NUM> is positioned under the patient's nose and seals against the external surfaces of the patient's nose.

The headgear of the disclosed technology may further comprise a pocket, tunnel, layers and/or ribs. Such structures may be formed in one piece by circular or flat knitting. The pockets or tunnels may be reinforced with materials having a higher stiffness or rigidity than the knitted textile, thereby rigidizing the headgear. Rigidizing the headgear may better stabilize the mask in position on the user's face. Materials used for rigidizing the headgear may include plastics such as nylon, polypropylene, polycarbonate, or higher stiffness textiles such as braided ropes. Preferably, the rigidizing of the headgear may be positioned at boney regions of the patient's head, for example the cheeks, occiput or crown. The reinforcing structure may be inserted during the knitting process, for example, a stiffer or flatter yarn or a rigid polymer element may be inserted into the knit construction, during or after the knitting process. The strands or rigid components would function to withstand tension and bear the stresses e.g., due to tightening of the headgear straps for therapy, or to stabilise the mask better, or would assist to act as coupling or fastening agents to attach the headgear piece(s) to the mask interface.

Alternatively, the pockets or tunnels may be cushioned to add comfort. For example, pockets or tunnels may be filled with foam, gel, floating yarn, looped yarn or other cushioning material.

Preferably, the headgear is formed by flat knitting or circular knitting, wherein the headgear has selvedges. That is, the headgear may be formed to have a finished configuration such that the ends of the yarns used to construct the headgear are substantially absent from the edges of the headgear components. An advantage of fashioning the headgear components to the finished shape is that the yarns are not being cut, and are thus less likely to unravel and may require fewer finishing steps. By forming finished edges, the integrity of the headgear is maintained or even strengthened and fewer or no post-processing steps are required to either (<NUM>) prevent unravelling of the headgear component and/or (<NUM>) create an edge that is distinct yet soft (such as in ultrasonically cutting and sealing a 'soft edge' on a fabric-foam-fabric laminate material) and/or (<NUM>) enhance the aesthetic and durability characteristics of the headgear.

The headgear of the disclosed technology may be formed by a regular or irregular pique knit. A pique knit will orient a first yarn on the right side (non-patient contacting side that is visible once headgear is donned) and a second yarn on the wrong side (the patient contacting side that is not visible once the headgear is donned). That is, the yarn exposed on the right side may be different to the yarn exposed on the wrong side. For example, the yarn on the right side may have a pleasant visual appearance and the yarn on the wrong side may have a nice hand feel for contacting the patient's skin. Alternatively, or in addition, the yarn on the right side may have a first moisture wicking property and the wrong side may have a second moisture wicking property. For example, the yarn on the right side may have a high percentage of microfiber having a first moisture wicking property and the wrong side may have a high percentage of non-microfiber having a second moisture wicking property.

The headgear may be preferably formed as a unitary knit structure which may also be uniform in material and properties, for simplicity, but preferably it will be formed as a unitary structure including various sections that have different physical properties, joined in a seamless manner. The various sections may exhibit, for example but not limited to, different degrees of strength, abrasion resistance, wear resistance, flexibility, enhanced durability, higher or lower moisture absorption (moisture absorbability), moisture-wicking ability, water affinity, breathability or air-permeability, liquid permeability, stretch or stretch-resistance, compressibility, cushioning ability, support, stiffness, recovery, fit, and form. The various sections may be constructed to exhibit variations in directional stretch, such as four way stretch, or bi-directional stretch, a tailored level of stretch resistance, or no stretch. This may be achieved by, for example but not limited to, selecting a particular yarn or knit construction type.

The headgear as a unified seamless structure may be formed in one piece with uniform characteristics, or from two or more sections with varying characteristics. The two or more headgear sections may differ by way of using two or more different yarns of different twist, denier, fibre composition, etc., thus imparting different physical properties to the headgear structure. The two or more headgear sections may differ by way of using two or more various knit stitch types, thus imparting unique physical properties to the two sections.

Whereas one region may incorporate, for example, elastane or PBT (Polybutylene terephthalate polyester) to enhance stretch, the other region may incorporate, for example, nylon or polyester to enhance durability. Similarly, while one region of the headgear may incorporate yarn with one denier, the other region may include a yarn with a greater or reduced denier, crimp or texture, in order to customize the cushioning, thickness or bulk.

The two or more sections within a headgear construction may be connected by using tuck stitches or other knit stitches that, for example, join a first section to a second section in a seamless manner. This would be achieved by knitting the first section, then knitting the tuck stitches between the first knitted section and a second knitted section, then knitting the second section. The tuck stitches are utilized to seamlessly connect sections between wales, especially when using a narrow-tube circular knitting machine.

The headgear piece may be finished without a seam. If it is made with an undyed yarn, this may be achieved by finishing the knitting process with a yarn that contains water-soluble fibres. The water-soluble fibers permit the fabric to shrink in the dyeing process and provides a neatly-finished edge, eliminating the need to create an additional seam on the edge.

In order to enhance manufacturing efficiency, knitting machines may also be utilized to form a series of joined headgear components, such as straps or crown components. That is, the knitting machines may form a single component that includes a plurality of headgear pieces. Each of the headgear segments may have substantially identical shapes and sizes. Alternatively, each of the headgear pieces may even have different shapes and sizes, which may be programmed in sequence. Moreover a knit release area (which may consist of, for example but not limited to, dissolvable yarns, loosely knitted yarns, finer denier yarns or easy-to-tear placeholder yarns) may be knitted into the series of headgear components in order to allow the various headgear parts, for example, straps, to be separated without the need for cutting operations.

In an example of the disclosed technology, headgear may be formed using spacer fabric material. A spacer fabric can be defined as a textile having an upper ground structure or layer, a lower ground structure or layer, and a floating or traversing yarn woven between the upper ground structure and lower ground structure to form a matrix like textile. The upper ground structure and lower ground structure may be formed from a fabric. The upper ground structure may have different properties to the lower ground structure, for example they may have different stretch, stiffness, flexibility, hand feel, or other characteristics. The upper and lower ground structures may be substantially parallel to one another. Spacer fabrics may be formed by flat knitting. At least one side (i.e. upper or lower ground structure) may be formed from a fabric having yarn of, for example, about <NUM>-<NUM> denier, <NUM>-<NUM> denier, or <NUM>-<NUM> denier for a pleasant hand feel.

In the example of <FIG>, a rear portion <NUM> includes an inner fabric <NUM> for interfacing with a patient, an outer fabric <NUM>, and spacer threads <NUM> joining the inner and outer fabrics. The inner fabric <NUM> may be configured to be soft and capable of wicking moisture in order to enhance comfort. The outer fabric may be designed to have a low friction surface so as to enable movement while sleeping without disrupting the position of the mask. The outer fabric may also have an anti-soil surface and may further include unbroken loop to facilitate attachment of straps.

In another example, headgear may be formed as a knitted tube having an inner space <NUM>, as shown in <FIG>. A tubular headgear piece <NUM> includes an outer fiber/interfacing fabric <NUM>, an inner spacer fiber or pile (connecting layer) <NUM>, and an inner fiber/fabric <NUM>. The tubular piece <NUM> is constructed by a device having inner and outer needles <NUM>,<NUM> which may be programmed to knit the outer fiber/interfacing fabric <NUM>, the inner spacer fiber, and the inner fiber/fabric <NUM>.

The tubular piece <NUM> may flatten out in use, when under tension, to form a low profle headgear piece (e.g., a strap), as shown in <FIG>. Further, referring to <FIG>, a tubular strap <NUM> may have a varying diameter such that a portion connecting to the rear portion <NUM> is wider than the ends adapted to connect to the mask. This configuration may reduce the visual obtrusiveness of the headgear strap <NUM>.

In another example, the inner space <NUM> may be configured to transit air, thus forming an air delivery conduit. PCT Application PCT/AU2012/<NUM>, filed June <NUM>, <NUM>, describes air delivery conduits that are made of textile or fabric materials. Such air delivery conduits described in the <CIT> application may be manufactured to shape (or fully-fashioned) as described according to any of the examples described in this application, and further may be implemented into any of the examples described in this application.

Turning to <FIG>, the depth or thickness of the headgear may be varied by altering the length of the spacer yarns (spacer threads). A headgear piece <NUM> includes an inner fabric <NUM>, an outer fabric <NUM>, and spacer threads <NUM>. The headgear piece <NUM> may include thinner regions <NUM> and thicker regions <NUM>. In the example of <FIG>, a gradual transition between the thinner regions <NUM> and the thicker regions <NUM> is formed. In contrast, a steeper transition can be seen in the example of <FIG>. One benefit of a tailored cushion with differing thicknesses might be cushioning which changes in thickness to correspond to certain facial bone/muscle structure creating contour, comfort and padding, or thinner zones for breathability and temperature management.

Referring to <FIG>, the thickness of a strap <NUM> can also be varied to create rigid portions <NUM> and connecting portions <NUM>. The rigid portions <NUM> may function as rigidizers or stabilizers and provide form in certain areas of the headgear. The connecting portions <NUM> may include a hole or other structure utilized to connect the strap <NUM> to a mask.

In addition to varying the depth or thickness of the headgear, gaps may be formed in the spacer threads. These gaps may be utilized to form vent holes in a mask or create flexible areas of the headgear, for example. In <FIG>, a mask <NUM> includes an inner fabric <NUM>, an outer fabric <NUM>, and spacer threads <NUM>. Voids <NUM> in the spacer thread may be used to create vent holes <NUM> in the mask. To facilitate this feature, the inner <NUM> and outer <NUM> fabrics are thinned in the areas of the voids <NUM>. Ends of the mask may be welded, knit, or joined in any other suitable manner.

Alternatively, the voids <NUM> may be thermoformed or otherwise compressed to form thinned regions <NUM>, as shown in <FIG>. The thinned regions <NUM> may form hinges or areas adapted to bend the headgear around a curve (e.g., around the patient's occiput).

In a further example, the spacer threads <NUM> may be unevenly spaced to create less dense areas <NUM> and more dense areas <NUM>. These areas may permit flexibility of the headgear to be adjusted as desired. For example, the headgear may be stiffer (dense area <NUM>) at the cheek bone region and flexible (less dense <NUM>) at the cheek muscle region.

In alternative examples, the headgear <NUM> and the headgear <NUM> of <FIG> and <FIG> may include spacer material, as shown in the cross-sectional views of <FIG> and <FIG>. The spacer fabric construction may provide more cushioning, breathability, moisture management (e.g. moisture absorbability or wicking), and/or desirability (e.g., comfort and/or aesthetic appeal).

Referring to <FIG>, the upper headgear strap <NUM> may include an inner fabric <NUM>(<NUM>), an outer fabric <NUM>(<NUM>), and spacer yarns. <NUM>(<NUM>). Further, the edge of the strap <NUM> may be knitted to draw the outer fabric <NUM>(<NUM>) into engagement with the inner fabric <NUM>(<NUM>) to create an integrated seamless edge <NUM>(<NUM>). Alternatively, the inner and outer fabrics may be welded (e.g., ultrasonic welded) at the edge of the strap <NUM>.

Referring now to <FIG>, the crown strap <NUM> may include an inner fabric <NUM>(<NUM>), an outer fabric <NUM>(<NUM>), and spacer yarns <NUM>(<NUM>). Additionally, the outer fabric <NUM>(<NUM>) may be brushed or otherwise treated to form unbroken loop material for receiving hook material.

Alternatively, the headgear may be constructed by braiding, crocheting, a net construction or raschel pattern, a single layer knit or a double layer knit such as an interlock or jersey, or even via additive manufacture (3D printing). In the case of a basic single face fabric or double face knit, it may be preferable to use a textured yarn which may provide appropriate cushioning and bulk, to enhance comfort to the patient.

Referring to <FIG>, a warp knitted strap <NUM> formed of spacer fabric is shown. The strap <NUM> includes an inner fabric <NUM>, an outer fabric <NUM>, and spacer yarns <NUM>. The strap may be formed of nylon and/or polyester, or any other suitable materials. The inner fabric <NUM> and the outer fabric <NUM> may have a soft surface having a high density. The strap may have a wider portion <NUM> adapted to connect to another headgear member (e.g., a rear portion) and a thinner portion <NUM> adapted to connect to a mask. The spacer yarns or pile may be formed to be shear resistant. The inner and outer fabrics are knitted together at the selvedges <NUM> to enclose the spacer pile. In another example, as shown in <FIG>, the outer fabric <NUM> includes unbroken loop material <NUM> for receiving hook material.

In an example, as shown in <FIG>, d1 may be about <NUM>-<NUM>, e.g., <NUM>, d2 may be about <NUM>-<NUM>, e.g., <NUM>, d3 may be about <NUM>-<NUM>, e.g., <NUM>, d4 may be about <NUM>-<NUM>, e.g., <NUM>, and d5 may be <NUM>-<NUM>, e.g., <NUM>. Further, as shown in <FIG>, d1 may be about <NUM>-<NUM>, e.g., <NUM> and d2 may be about <NUM>-<NUM>, e.g., <NUM>.

<NUM>-<NUM> to <NUM>-<NUM>, a warp knitted strap <NUM> includes an inner fabric <NUM>, an outer fabric <NUM>, and spacer yarns <NUM>. In contrast to the strap <NUM> above, the strap <NUM> has a constant width. The spacer yarns or pile may be formed to be shear resistant. The inner and outer fabrics are knitted together at the selvedges <NUM> to enclose the spacer pile. In another example, as shown in <FIG>, the outer fabric <NUM> includes unbroken loop material <NUM> for receiving hook material. In a further example the outer fabric <NUM> may be elasticated to form a high-tension outer fabric <NUM>-<NUM>, as shown in <FIG>. The elasticated outer fabric <NUM>-<NUM> pulls the selvedges <NUM> to the outer surface of the strap, and may function to cause the headgear strap to curl upwards and inwards towards the outer fabric layer of the strap. In cross section, as shown in <FIG>, the strap may have the appearance of the letter C. This arrangement may be advantageous in reducing facial marking as the strap does not have a distinct edge when pressed against the patient's skin, since the edge curls up away from the skin.

In an example, as shown in <FIG>, d1 may be about <NUM>-<NUM>, e.g., <NUM>, d2 may be about <NUM>-<NUM>, e.g., <NUM>, and d3 may be about <NUM>-<NUM>, e.g., <NUM>.

Alternatively, in accordance with another example, headgear may be formed to shape having an inner and outer face with no space in between these faces. <FIG> is a schematic representation of a double knit and <FIG> illustrate an interlock knit. In <FIG>, an inner fabric <NUM> and an outer fabric <NUM> are knitted in such close proximity that they form a double faced fabric such as interlock, double knit or double jersey. As shown in <FIG>, the inner <NUM> and outer <NUM> fabrics are knitted at the same time with a spacer yarn <NUM> that pulls the inner <NUM> and outer <NUM> fabric layers together. However, in the example of <FIG>, the inner <NUM> and outer <NUM> fabrics are knitted concurrently (at the same time) without the need for an additional spacer yarn in a manner commonly known as interlock, whereby there are two sets of yarns which form the inner and outer fabric respectively.

Double faced or knit fabrics may be beneficial for use in headgear as the fabric may be flatter (i.e. thinner in fabric thickness, not thinner in strap width) than most conventional headgear materials (e.g. foam laminate) so as to be as unobtrusive as possible for the patient, but more substantial, dense, durable, robust or stiff than a single-knit. A double knit fabric may also permit a first characteristic or pattern/structure on one side of the fabric with a second characteristic or pattern/structure on the opposite side of the fabric. For example, a soft yarn may be provided on the patient contacting side, and a more durable yarn or construction on the non-patient contacting side. In a further example, a wicking microfiber may be provided on the patient contacting side and a hydrophilic material may be provided on the non-patient contacting side. In a further example a cotton yarn may be provided on the patient contacting side and a polyester outer may be provided on the non-patient contacting side. A double knit fabric may be preferable to a spacer fabric as the double knit may be less expensive and less complex due to the smaller number of layers.

The number of stitches can be adjusted to enhance comfort, fit and/or performance. For instance, the number of stitches may be varied to create ruffles which may function to reduce facial marking. In the example of <FIG>, a mask <NUM> is supported by headgear <NUM>. The mask includes a seal portion <NUM> which seals against the patient's face. The headgear <NUM> includes straps <NUM> and may also include an upper strap <NUM> to assist in stabilizing the mask. The number of stitches through a middle portion <NUM> of the straps <NUM> is less than the number of stitches near the outer edge of the straps. The increased number of stitches at the edge portion causes the strap to form ruffles <NUM>. It will be understood that the number of stitches may be adjusted in any portion of the headgear to achieve a desired fit.

Referring back to <FIG>, the number of stitches in the rear portion <NUM> may be adjusted to cause the rear portion to form a shape configured to conform to a patient's head. The truncated cone shape in <FIG> is shown to illustrate an example of adjusting the number of stitches to change the shape. For example, a distal portion <NUM> of the rear portion <NUM> may have fewer stitches than a proximal portion <NUM>. In an example, the distal portion may be comprised of <NUM> stitches and the proximal portion may be comprised of <NUM> stitches. This arrangement may cause the proximal portion to have an increased diameter thereby flaring outwardly into a truncated cone shape.

In another example, the thread count may vary across the fabric to enhance comfort, fit and/or performance. For example, the thread count may be higher in regions requiring greater stiffness (e.g., cheek region, occiput). In regions (e.g., along the straps) where a lower stiffness is desired, however, the thread count may be lower thereby permitting the material to flex more easily.

The thread count, and therefore the stiffness, may be determined by the type of yarn, the type of stitch (e.g., a criss-cross stitch may be stiff), and the distance between stitches.

The headgear may include one or more rigidizers that are structured to add rigidity, stiffness and/or stability to the headgear and anchor the headgear in position in use. In an example, a rigidizer is formed integrally with a strap. For instance, in <FIG> and <NUM>-<NUM>, yarn having a higher stiffness than the surrounding yarn of the headgear <NUM> may be knitted in specific regions (e.g., cheek region or crown region) to form a rigidizer <NUM>. The rigidizer <NUM> may stiffen the headgear to provide stability for the mask. In addition, the rigidizer <NUM> may be shaped to form a headgear clip <NUM> for attachment to a patient interface <NUM> (e.g., nasal mask).

In another example, the yarn forming the rigidizer <NUM> may be melted or fused to further stiffen the yarn into a welded rigidizer <NUM>, as shown in <FIG>. Preferably, the rigidizer yarn has a lower melt temperature than the surrounding yarn such that the welded rigidizer <NUM> can be formed without deforming the surrounding yarn. In an example, the rigidizer yarn includes polypropylene and the surrounding yarn includes nylon or other non-plastic material such as cotton or wool.

The knitted headgear component may incorporate a thermoplastic yarn that is fused in different regions of the knitted component to impart different properties. By heating the thermoplastic polymer materials, adjacent yarns, filaments, or fibers may fuse to each other in those areas to lock the knit loops together, thereby increasing stiffness or wear-resistance or stability of the mask on the patient's face. As an alternative, the entirety of the knitted headgear component may be formed from yarns that incorporate thermoplastic polymer materials, and only specific portions corresponding with fused areas may be heated to modify the properties.

The rigidizer may be formed by a flat tool <NUM>, as shown in <FIG>, or a curved tool <NUM>, as shown in <FIG>. In <FIG>, a curved headgear <NUM> having a curved rigidizer <NUM> is formed.

The inner or outer layer of headgear fabric may be formed to include a slit (or gap). A rigid or semi-rigid element may be inserted through the slit to form a support positioned between the inner layer and the outer layer of the headgear. In an example shown in <FIG>, a similar hollow structure (to <FIG>) could also be knitted in a flattened-out manner, for instance on a warp knitting machine, by concurrently knitting an outer fabric <NUM>-<NUM>, that interfaces with the patient, to a layer of spacer yarns <NUM>-<NUM>, which at the same time is knitted to an inner fabric <NUM>-<NUM> that encases the spacer yarns, which is covered in turn by knitting a pocket layer <NUM>-<NUM> that forms a gap <NUM>-<NUM> (or pocket). The pocket layer <NUM>-<NUM> is connected to the outer fabric <NUM>-<NUM>, the spacer yarns <NUM>-<NUM> and/or the inner fabric <NUM>-<NUM> only near the selvedge <NUM>-<NUM> of the knitted structure.

As shown in <FIG>, the gap <NUM>-<NUM> could form a hollow pocket in a strap <NUM>-<NUM>, for example, which may be filled with a separate rigidizer <NUM>-<NUM>, for example, or may be used to locate another related mask component or attachment mechanism. The spacer fabric provides a soft cushioning between a hard part (e.g., the rigidizer <NUM>-<NUM>) and the patient's face, and the pocket functions to locate a hard plastic part or cushion attachment into the soft fabric headgear strap encasement, which may be fastened in place by, for example, friction, clips, adhesives, heat laminate or overstitching.

Yarn may be utilized to create the headgear of the disclosed technology.

The yarn may be synthetic, and may be twisted or textured, and could be made from, but not limited to nylon, polyester, acrylic, rayon, or polypropylene. The yarn could be a conventional staple yarn, a microfiber yarn, or combination of both.

The yarn may incorporate an elastane fiber or filament to provide stretch and recovery properties, such as fibers bearing the LYCRA trademark from the DuPont company.

The yarn may be made of synthetic materials, or natural fibres such as cotton, wool or bamboo, or natural filament such as silk.

The yarns used to construct any component of the headgear may be formed of a monofilament or a plurality of single filaments, that is, a multifilament yarn.

The yarn may include separate filaments that are each formed of different materials. The yarn may also include filaments that are each formed of two or more different materials, such as bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist or crimping, as well as different deniers, may affect the properties of the headgear.

The materials utilized to construct the headgear components may be made recyclable or biodegradable, for example, the yarns may include recyclable or biodegradable fibers or filaments.

Areas of the headgear subject to greater wear (for example but not limited to areas or regions coming into contact with a patient's pillow), such as an area of headgear located at the back of the head or nape of the neck, may possibly be more densely fabricated and may thus be a heavier weight and less extensible. Conversely, this area may be subject to the greatest amount of moisture accumulation through sweat, and therefore may need to be made of a thin, yet strong, net-like construction with a custom aperture pattern. In this case, the abrasion-resistance may need to be inherent in the yarn properties only.

In another example, headgear may be manufactured to shape using a 3D printer. As shown in <FIG>, a 3D printer may be used to print a plurality of connected links <NUM> thereby forming a flexible 3D printed textile <NUM>. Referring to <FIG>, a headgear piece <NUM> may be formed to include a rigidizer <NUM>. The rigidizer includes holes <NUM> through whieh the links of the textile <NUM> may pass as the textile is printed to integrate the textile and the rigidizer. The rigidizer could be made from any suitable material (e.g., a polymer such as Nylon <NUM> or a sintered solid from a metal powder, or any other material able to used for an additive manufacture process). As the additive manufacture ("3D Printing" process technologies improve, it is envisioned that the material selection will become broader for the purposes of 3D printing textiles, with the optional inclusion of a rigid component. Structure could be inherent in material or by virtue of structure.

Further, as shown in <FIG>, a 3D printed strap <NUM> may be integrated into holes <NUM>(<NUM>), <NUM>(<NUM>) of male and female clips <NUM>, <NUM>.

Custom headgear may be manufactured for an individual patient in accordance with an example of the disclosed technology. Data regarding the shape and size of the patient's head is acquired (e.g., via photo, 3D scan). Measurements that may be used to manufacture a custom headgear may include the circumference of the patient's crown, length from the occiput to the crown, and the position of the patient's ears, eyes and nose. Visual modeling software (e.g., CADCAM) operating on a computer may create a custom headgear model according to the patient's measurements and needs. This model may then be sent to a machine (e. g, a knitting machine or 3D printer) for creation of the headgear.

It is noted that features of the disclosed technology have been particularly described with reference to headgear. However, all of the features described in relation to headgear may also be usable in any mask constructed in accordance with the disclosed technology.

Claim 1:
A mask system for treating a patient for sleep disordered breathing, comprising:
a respiratory mask adapted to seal against a patient's face thereby forming a breathing cavity for positive pressure treatment of the patient; and
headgear for use in supporting the respiratory mask in position on the patient's face for positive pressure treatment of the patient, the headgear comprising:
a knitted tube formed of a unitary seamless structure that is formed in one piece to shape without the need to cut away substantial amounts of material; and
a rear portion,
wherein the knitted tube has a portion connecting to the rear portion.