# US 2014/0190486 A1 · Ultrasonic welding of fabrics for sleep apnea treatment > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0190486 A1 - Document ID: US20140190486A1 - Status: Published application - Kind: A1 - Application number: 14/240,167 - Filed: 2012-08-22 - Published: 2014-07-10 - Earliest claimed: 2011-08-22 - Assignees: ResMed Limited - Inventors: Jessica Lea Dunn; Grant Milton Ovzinsky; Anthony Paul Barbara; Kirrily Michele Haskard; Justin John Formica; Michael Charles Laguzza - Web page: https://patentgrep.com/patent/US20140190486A1 ## CPC - A61M 16/0683: {Holding devices therefor} - B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)} - B29C 65/7443: {by means of ultrasonic vibrations} - B29C 66/1142: {Single butt to butt joints} - B29C 66/14: {the joint having the same thickness as the thickness of the parts to be joined (B29C66/1142 takes precedence)} - B29C 66/43: {Joining a relatively small portion of the surface of said articles (B29C66/45 takes precedence)} - B29C 66/4322: {by joining a single sheet to itself (B29C66/4332 takes precedence)} - B29C 66/4344: {Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces} - B29C 66/43441: {with two right angles, e.g. for making T-shaped pieces, H-shaped pieces} - B29C 66/436: {Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats (joining through openings B29C66/304)} - B29C 66/729: {Textile or other fibrous material made from plastics} - B29C 66/73521: {of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part} - A61M 16/0633: {with forehead support} - A61M 2207/00: Methods of manufacture, assembly or production - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B29C 65/4815: {Hot melt adhesives, e.g. thermoplastic adhesives} - B29C 65/5042: {covering both elements to be joined} - B29C 65/62: Stitching - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)} - B29C 66/727: {being porous, e.g. foam} - B29L 2031/4835: {Masks} - F04C 2270/0421: Controlled or regulated - A61M: DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY (introducing media into or onto the bodies of animals A61D7/00; means for inserting tampons A61F13/26; devices for administering food or medicines orally A61J; containers for collecting, storing or administering blood or medical fluids A61J1/05); DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY (surgery A61B; chemical aspects of surgical articles A61L); DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR {(Electrotherapy, e.g. producing anaesthesia by the use of alternating or intermittent currents A61N1/36021)} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - F04C: ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS (engines F03C); ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS ## Abstract 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. ## Claims ### Claim 1 A. method of making headgear for use in holding a respiratory mask in position on a patient's face, comprising: forming at least first and second headgear components, the first and second headgear components including at least a fabric material; overlapping the at least first and second headgear components in an ultrasonic welding tool; ultrasonically welding together the at least first and second headgear components to form an ultrasonic welding joint and to shape one of the at least first and second headgear components, thereby forming at least one headgear section; and removing an overlapping portion of the at least first and second headgear components. ### Claim 2 (depends on 1) The method of making headgear according to claim 1, further comprising thermoforming the at least first and second headgear components before the ultrasonic welding step. ### Claim 3 The method of making headgear according to any of the proceeding claims, wherein the first and second headgear components each have a patient interface surface, the first headgear component has a thickness that is greater than a thickness of the second headgear component, and the patient interface surfaces of the first and second headgear components are aligned to provide an even contact with the patient. ### Claim 4 The method of making headgear according to any of the proceeding claims, wherein the first and second headgear components respectively are first and second straps, the first strap has a first vector, and the second strap has a second vector different from the first vector. ### Claim 5 (depends on 1, 2) The method of making headgear according to claim 1, 2, or 4, wherein the at least one headgear section has a substantially uniform thickness. ### Claim 6 The method of making headgear according to any of the proceeding claims, wherein the ultrasonic welding joint includes a thinned portion having increased flexibility, the method further comprising overlapping the at least first and second headgear components and/or removing the overlapping portions in a manner that locates the ultrasonic welding joints to allow or disallow flexibility in at least one portion of the at least one headgear section. ### Claim 7 The method of making headgear according to any of the proceeding claims, wherein the first headgear component is a substantially flat member and the second headgear component is a curved member, and the curved member is attached at an edge portion of the flat member to provide a rounded edge. ### Claim 8 The method of making headgear according to any of the proceeding claims, wherein the first headgear component is a strap and the second headgear component is a fastening member, the overlapping portion is removed from the strap, and the fastening member is nested within the strap in a recessed manner. ### Claim 9 The method of making headgear according to any of the proceeding claims, wherein the first component is a more rigid less flexible member and the second component is a more flexible less rigid member, the method further comprising alternating the first component and the second component to allow or disallow flexibility in at least one portion of the at least one headgear section. ### Claim 10 (depends on 9) The method of making headgear according to claim 9, wherein the first component is foam and the second component is a textile. ### Claim 11 A method of making a comfort pad for use with headgear in holding a respiratory mask in position on a patient's face, comprising: ultrasonically welding a padded member to a first substantially flat member thereby forming a first ultrasonic welding joint, wherein the padded member is arranged to provide a cushion between the patient and the headgear, and the first flat member is arranged to overwrap the headgear to position the padded member. ### Claim 12 (depends on 11) The method of making a comfort pad according to claim 11, wherein the padded member includes a foam layer. ### Claim 13 (depends on 11, 12) The method of making a comfort pad according to claims 11-12, wherein first flat member includes hook material and/or unbroken loop. ### Claim 14 (depends on 11, 12, 13) The method of making a comfort pad according to claims 11-13, further comprising ultrasonically welding a second substantially flat member to the padded member thereby forming a second ultrasonic welding joint, the second flat member being joined to the padded member on an opposite side of the padded member than the first flat member. ### Claim 15 A method of forming a mask assembly for use in treating a patient for sleep disordered breathing, comprising: ultrasonically welding a first component to a second component thereby forming at least a first mask section, wherein the first mask section at least partially forms a cavity adapted to deliver pressurized air to the patient. ### Claim 16 (depends on 15) The method of forming a mask according to claim 15, further comprising ultrasonically welding a dart into the first mask section to form a three-dimensional shape. ### Claim 17 (depends on 15, 16) The method of forming a mask according to claims 15-16, further comprising connecting the first mask section to at least one conduit for delivery of the pressurized air. ### Claim 18 A mask assembly for use in treating a patient for sleep disordered breathing, comprising: a first component; a second component; and an ultrasonic welding joint interconnecting the first component and the second component thereby forming at least a first mask section, wherein the first mask section at least partially forms a cavity adapted to deliver pressurized air to the patient. ### Claim 19 (depends on 18) The mask assembly of claim 18, further comprising at least one conduit connected to the first mask section for delivery of the pressurized air. ### Claim 20 Headgear for 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; a second headgear component, the first and second headgear components including at least a fabric material; and an ultrasonic welding joint interconnecting the first headgear component and the second headgear component thereby forming at least a first headgear section, wherein a space is formed between the first and second headgear components. ### Claim 21 (depends on 20) Headgear according to claim 20, wherein the space forms a pocket and a rigidizer is disposed in the pocket. ### Claim 22 (depends on 20, 21) Headgear according to claims 20-21, wherein the ultrasonic welding joint is distal to a patient contacting surface of the first headgear section. ### Claim 23 (depends on 20, 21, 22) Headgear according to claims 20-22, wherein the space forms a strap tidy to receive a free end of one of the first and second headgear components. ### Claim 24 A method of making headgear for use in holding a respiratory mask in position on a patient's face, comprising: ultrasonically welding a first headgear component to a second headgear component thereby forming at least a first headgear section having a space situated between the first headgear component and the second headgear component, the first and second headgear components including at least a fabric material. ### Claim 25 (depends on 24) The method of making headgear according to claim 24, wherein the ultrasonic welding step includes forming at least one ultrasonic welding joint, and the ultrasonic welding joint is located distal to a patient contacting surface of the first headgear section. ### Claim 26 (depends on 24, 25) The method of making headgear according to claims 24-25, wherein the space forms a strap tidy to receive a free end of one of the first and second headgear components. ### Claim 27 (depends on 24, 25, 26) The method of making headgear according to claim 24-26, wherein the space forms a pocket and a rigidizer is disposed in the pocket. ### Claim 28 (depends on 27) The method of making headgear according to claim 27, further comprising applying heat to set the rigidizer in place. ### Claim 29 Headgear for 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 formed of a first fabric; a second headgear component formed of a second fabric, the second fabric being softer than the first fabric; and an ultrasonic welding joint interconnecting the first headgear component and the second headgear component thereby forming at least a first headgear section, wherein the first and second headgear components are connected to one another, the second headgear component adapted to cover a portion of the first headgear component proximal to the patient. ### Claim 30 A method of making headgear for use in holding a respiratory mask in position on a patient's face, comprising: nesting first headgear components in at least one sheet of material; nesting second headgear components in the at least one sheet of material; cutting the first and second headgear components from the at least one sheet of material; and ultrasonically welding the first headgear components and the second headgear components to form at least one headgear section. ### Claim 31 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 strap having a first vector; a second strap having a second vector different from the first vector; and an ultrasonic welding joint interconnecting the first strap and the second strap thereby forming at least a first headgear section. ### Claim 32 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 substantially flat member including at least a fabric material; and a curved member joined to the flat member by ultrasonic welding thereby forming a substantially seamless join, wherein the curved member is attached at an edge portion of the flat member to provide a rounded edge to increase comfort for the patient.