Respiratory mask with molded frame and cushion

Abstract

A respiratory mask has an adjustable forehead support member that is simple and inexpensive to manufacture. The forehead support member may be adjusted by rotating a forehead pad about an off-center bore or by bending an angular adjustment beam. The mask has a mask cushion with an accordionate membrane having at least two hinged portions. The mask may be constructed with a mask frame, the mask cushion, and the forehead support member molded as one piece.

What is claimed is: 
     
         1 . A respiratory mask comprising:
 a mask frame including a forehead support member and a plurality of strap attachment portions, integral to at least one of the mask frame and the forehead support member, for attaching straps to the respiratory mask to mount the respiratory mask on a facial region of a user;   a forehead pad attached to the forehead support member, wherein an angle of the mask frame relative to the facial region of the user is adjusted by rotating the forehead pad.   
     
     
         2 . The respiratory mask of  claim 1  wherein the forehead pad has a bore, the forehead support member of the mask frame being inserted into the bore. 
     
     
         3 . The respiratory mask of  claim 2  wherein the bore is an off-center square bore having four inward facing surfaces and the forehead support member has a rectangular cross-section having four outward facing surfaces, wherein each parallel pair of inward facing surfaces is parallel to a pair of outward facing surfaces, and whereby the forehead pad can be fit to the forehead support member in four distinct positions, each position providing a distinct distance different from the others of an outward facing surface of the forehead pad contacting the facial region from an inward facing surface of the forehead pad contacting the forehead support member. 
     
     
         4 . The respiratory mask of  claim 2  wherein the bore has a plurality of inward facing surfaces and the forehead support member has a cross-section with a corresponding number of outward facing surfaces, wherein each inward facing surface is parallel to an outward facing surface, whereby the forehead pad can be fit to the forehead support member in a corresponding number of distinct positions, each position providing a distinct and different distance of an outward facing surface of the forehead pad contacting the facial region from an inward facing surface of the forehead pad contacting the forehead support member. 
     
     
         5 . The respiratory mask of  claim 2  wherein the bore is circular and an outer surface of the forehead pad is a single continuous surface, which is not a concentric circle of the bore, whereby the distance of a location on the outer surface of the forehead pad contacting the facial region from an inward facing surface of the forehead pad contacting the forehead support member is continuously variable by rotating the forehead pad. 
     
     
         6 . The respiratory mask of  claim 2  wherein an inward facing surface of the bore and the forehead support member are constructed and arranged to allow manual rotation of the forehead pad and resist accidental rotation of the forehead pad. 
     
     
         7 . The respiratory mask of  claim 2  wherein the forehead support member and the forehead pad have cooperative interlocking structure to resist the forehead support member coming out of the bore. 
     
     
         8 . The respiratory mask of  claim 1  further comprising a substantially ring-shaped mask frame mask cushion interposed between the mask frame and the facial region of the user, the mask frame mask cushion comprising a single, continuous, accordion-shaped wall with at least two hinge portions. 
     
     
         9 . The respiratory mask of  claim 8  wherein the mask frame mask cushion is integrally formed with the mask frame. 
     
     
         10 . The respiratory mask of  claim 9  wherein the mask frame and the mask frame mask cushion are molded as a single piece. 
     
     
         11 . The respiratory mask of  claim 9  wherein the mask frame mask cushion is molded over the mask frame. 
     
     
         12 . The respiratory mask of  claim 11  wherein a plurality of channels in the mask frame allow a cushion molding material, which forms the mask frame mask cushion, to bleed through the mask frame during a molding process. 
     
     
         13 . A respiratory mask comprising:
 a mask frame having a forehead support member and a plurality of strap attachment portions, integral to at least one of the mask frame and the forehead support member, for attaching straps to the respiratory mask to mount the respiratory mask on a facial region of a user; and   a flexible beam between the mask frame and the forehead support member, whereby an angle of the mask frame relative to a facial region of the user is adjusted by bending the flexible beam.   
     
     
         14 . The respiratory mask of  claim 13  further comprising a substantially ring-shaped mask frame mask cushion interposed between the mask frame and the facial region of the user, the mask frame mask cushion comprising a single, continuous, accordion-shaped wall with at least two hinge portions. 
     
     
         15 . The respiratory mask of  claim 14  wherein the mask frame mask cushion is integrally formed with the mask frame. 
     
     
         16 . The respiratory mask of  claim 15  wherein the mask frame and the mask frame mask cushion are molded as a single piece. 
     
     
         17 . The respiratory mask of  claim 15  wherein the mask frame mask cushion is molded over the mask frame. 
     
     
         18 . The respiratory mask of  claim 17  wherein a plurality of channels in the mask frame allow a cushion molding material, which forms the mask frame mask cushion, to bleed through the mask frame during a molding process. 
     
     
         19 . A method of manufacturing a respiratory mask comprising;
 molding integrally a mask frame, a mask cushion, a forehead support member, a hinge connecting the mask frame to the cushioning seal, a hinge connecting the mask cushion to the forehead support member, and a cooperative interlocking structure on the mask frame and the mask cushion;   folding the mask frame relative to the mask cushion;   interlocking the cooperative interlocking structure whereby the mask frame is locked in a position relative to the mask cushion;   folding the forehead support member relative to the mask cushion, whereby the mask frame is interposed between the forehead support member and the mask cushion; and   attaching straps to the mask frame and the forehead support member to mount the mask on a facial region of a user.   
     
     
         20 . The method of  claim 19  further comprising molding a forehead pad integral to the forehead support member, during the first molding step.