Method of producing headgear structure for a breathing mask

Abstract

A headband for use in supporting a breathing mask on a user's face comprises a flexible band body that is provided with upper and lower band portions. At least some portions of the band body are made of a foamed plastic material. The headband may be provided with a supporting structure made of a material in which at least some portions of the supporting structure can be individually adjusted to the shape of the back of the user's head. A method for producing the headband and the supporting structure include injecting a plastic material into a first molding tool space to form a stiffening layer, subsequently, injecting a pore-forming plastic material into a second molding tool space such that the pore-forming plastic material at least partially covers the stiffening layer to form a cushion layer.

What is claimed is: 
     
         1 . A method for producing a headgear structure for use with a breathing mask, comprising:
 injecting a plastic material into a first molding tool space to form a stiffening layer;   subsequently, injecting a pore-forming plastic material into a second molding tool space such that the pore-forming plastic material at least partially covers the stiffening layer to form a cushion layer.   
     
     
         2 . The method of  claim 1 , wherein the headgear structure is a headband configured to be attached to the breathing mask to support the breathing mask on a patient's face. 
     
     
         3 . The method of  claim 1 , wherein a first portion of the headband has higher torsion stiffness than a second portion of the headband. 
     
     
         4 . The method of  claim 1 , wherein the stiffening layer comprises nylon or polyamide. 
     
     
         5 . The method of  claim 1 , wherein the headgear structure is a supporting structure configured to be attached to a headband to facilitate the headband in supporting the breathing mask on a user's face. 
     
     
         6 . The method of  claim 5 , wherein the cushion layer is located on an inner side of the supporting structure and adapted to face the user in an application position. 
     
     
         7 . The method of  claim 6 , wherein the supporting structure further comprises a coupling surface including an attachment structure configured to releasably couple the supporting structure with the headband such that the supporting structure is configured to be removably attachable to the headband. 
     
     
         8 . The method of  claim 7 , wherein the supporting structure has a layered arrangement and the cushion layer is positioned between the stiffening layer and the coupling surface. 
     
     
         9 . The method of  claim 8 , wherein the supporting structure is configured to be located at a back of the user's head. 
     
     
         10 . The method of  claim 8 , wherein the supporting structure is configured to be located at a height of the user's ear or in an area of an end of the user's cervical vertebra. 
     
     
         11 . The method of  claim 8 , wherein the supporting structure is adaptable to a shape of a user's head and which maintains the shape in a sufficiently dimensionally stable manner. 
     
     
         12 . The method of  claim 8 , wherein the stiffening layer comprises a thermo-deformable material. 
     
     
         13 . The method of  claim 12 , further comprising deforming the stiffening layer in accordance with the shape of an individual user's head. 
     
     
         14 . The method of  claim 13 , further comprising heating the stiffening layer to deform the stiffening layer. 
     
     
         15 . The method of  claim 14 , further comprising heating the stiffening layer to a temperature of at least 30° C. 
     
     
         16 . The method of  claim 15 , further comprising heating the stiffening layer to a temperature of at least 50° C. 
     
     
         17 . The method of  claim 12 , wherein the stiffening layer is at least partially pre-shaped in accordance with an estimated shape of a back of the user's head. 
     
     
         18 . The method of  claim 8 , wherein the cushion layer at least partially comprises a foamed and/or nonwoven material. 
     
     
         19 . The method of  claim 8 , wherein the cushion layer is at least partially embedded in a textile layer. 
     
     
         20 . The method of  claim 19 , wherein the textile layer is configured so as to at least partially provide the coupling surface. 
     
     
         21 . The method of  claim 8 , wherein the coupling of the supporting structure to the headband comprises a hook and loop fastener. 
     
     
         22 . The method of  claim 8 , wherein the stiffening layer comprises at least one opening. 
     
     
         23 . The method of  claim 8 , wherein the supporting structure is configured as a curved plate element. 
     
     
         24 . The method of  claim 8 , wherein the supporting structure comprises lower leg portions to guide respective lower band portions of the headband. 
     
     
         25 . The method of  claim 8 , wherein the supporting structure comprises upper leg portions to guide respective upper band portions of the headband. 
     
     
         26 . The method of  claim 8 , wherein the supporting structure is adapted to at least partially determine a course of the headband so as to increase the resistance of the headband against slipping and/or twisting. 
     
     
         27 . The method of  claim 8 , wherein the cushion layer is attached to both the stiffening layer and the coupling surface such that the cushion layer, the stiffening layer and the coupling surface are together removably attachable to the headband. 
     
     
         28 . The method of  claim 7 , wherein the cushion layer is attached to both the stiffening layer and the coupling surface such that the cushion layer, the stiffening layer and the coupling surface are together removably attachable to the headband.