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.

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.