Forehead-contacting device for a breathing mask and method for making the same

1. A method for forming a forehead-contacting device, comprising:

molding a support element from an elastomer material that includes a jacket defining a hollow chamber and a hollow support shaft portion, the jacket and the hollow support shaft portion being formed from one continuous piece of the elastomer material;

filling the hollow chamber with a viscous medium via the hollow support shaft portion;

forming the jacket using a mold core tool; and

unmolding the mold core tool via an inner conduit provided by the hollow support shaft portion of the jacket.

2. The method of claim 1 , wherein the viscous medium comprises a gel.

3. The method of claim 1 , further comprising closing the hollow chamber of the jacket with a closure device after the filling.

4. The method of claim 1 , further comprising closing the hollow chamber by gluing the hollow support shaft portion closed.

5. The method of claim 1 , further comprising closing the hollow chamber by clamping the hollow support shaft portion of the jacket with a collar element.

6. The method of claim 1 , further comprising closing the hollow chamber by supplying a cross-linking agent to the viscous medium to form a closure stopper of the hollow support shaft portion.

7. The method of claim 1 , wherein unmolding the mold core tool comprises pulling the mold core tool out along the inner conduit of the hollow support shaft portion of the jacket.

8. The method of claim 1 , wherein unmolding the mold core tool comprises blowing the jacket out from the mold core tool using a pressure medium.

9. The method of claim 1 , wherein unmolding the mold core tool comprises filling the hollow chamber with the viscous medium such that the jacket is positively displaced from the mold core tool.

10. The method of claim 1 , wherein unmolding the mold core tool comprises elastically widening the shaft hollow support portion via the inner conduit.

11. The method of claim 1 , further comprising:

forming an annular bead about the hollow support shaft portion; and

fixing a support plate element to said annular bead.

12. The method of claim 1 , wherein the hollow support shaft portion is structured to connect to a forehead support of a breathing mask.

13. The method of claim 1 , wherein the jacket is shaped to conform to a patient's forehead.

14. The method of claim 1 , wherein the one continuous piece of the elastomer material is homogeneous.

15. A method for forming a forehead-contacting device, comprising:

molding a support element from an elastomer material that includes a jacket defining a hollow chamber and a hollow support shaft formed in one piece with the jacket, by which the hollow chamber is adapted to be supported on a forehead support;

attaching a collar element to the hollow support shaft provided to the jacket;

inserting a closure plug element including a core conduit at least partway into the collar element and the hollow support shaft;

filling the hollow chamber with a viscous medium via the hollow support shaft and the core conduit of the closure plug element; and

further inserting the closure plug element into the hollow support shaft and the collar element to close the core conduit and hence close the hollow chamber and the hollow support shaft of the jacket.

16. The method of claim 15 , wherein the viscous medium comprises a gel.

17. The method of claim 15 , further comprising evacuating the hollow chamber via the core conduit before filling the hollow chamber with a viscous medium.

18. The method of claim 15 , further comprising:

forming the jacket using a mold core tool; and

unmolding the mold core tool via an inner conduit provided by the hollow support shaft of the jacket.

19. The method of claim 15 , further comprising:

forming an annular bead about the hollow support shaft; and

fixing a support plate element to said annular bead.

20. The method of claim 18 , wherein unmolding the mold core tool comprises pulling the mold core tool out along the inner conduit of the hollow support shaft of the jacket.

21. The method of claim 18 , wherein unmolding the mold core tool comprises blowing the jacket out from the mold core tool using a pressure medium.

22. The method of claim 18 , wherein unmolding the mold core tool comprises filling the hollow chamber with the viscous medium such that the jacket is positively displaced from the mold core tool.

23. The method of claim 18 , wherein unmolding the mold core tool comprises elastically widening the hollow support shaft via the inner conduit.