Cushion to frame assembly mechanism

1. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion/frame sub-assembly including:

a cushion frame comprising a cushion frame material, the cushion frame having a cushion frame wall having an opening that extends along a cushion frame longitudinal axis; and

a cushion connected to the cushion frame, the cushion being adapted to form a seal with at least a patient's upper airways and including a cushion material that is more flexible than the cushion frame material;

an outer frame snap-fit to the cushion/frame sub-assembly, the outer frame including:

an outer frame wall having an opening that extends along an outer frame longitudinal axis;

at least a first headgear attachment point;

a main body extending laterally relative to the opening;

a connection adjacent the opening that engages an elbow, wherein the connection, the main body, and the at least first headgear attachment point are formed as a one-piece construction, the connection having a length along the outer frame longitudinal axis that is greater than a thickness of the main body; and

a connection layer positioned along an inner surface of the connection; and

headgear including at least a first strap releasably attachable or clipped to the at least first headgear attachment point,

wherein the outer frame is removably interlocked with the cushion/frame sub-assembly by aligning the cushion frame longitudinal axis with the outer frame longitudinal axis, and moving the cushion/frame sub-assembly and the outer frame towards one another until they reach an interlocked position in which the outer frame wall and the cushion frame wall are at least partially nested relative to one another.

2. The mask assembly according to claim 1 , wherein the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame wall and the outer frame includes a surface that that extends radially relative to the outer frame wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the outer frame.

3. The mask assembly according to claim 1 , wherein the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly.

4. The mask assembly according to claim 1 , wherein the cushion frame is contoured to fit over the patient's nose and mouth.

5. The mask assembly according to claim 1 , wherein the outer frame includes contact points to help prevent rotation of the cushion frame with respect to the outer frame.

6. The mask assembly according to claim 1 , wherein the cushion frame and the cushion together at least partly form a breathing chamber around the patient's nose and mouth.

7. The mask assembly according to claim 1 , wherein the cushion frame includes a continuous protrusion, and the outer frame includes a perimeter frame member that engages the continuous protrusion.

8. The mask assembly according to claim 1 , wherein the at least first headgear attachment point includes first and second headgear attachment points that are adjacent to and on substantially opposite lateral sides of the connection.

9. The mask assembly according to claim 1 , wherein the cushion frame and the outer frame have complementary shapes.

10. The mask assembly according to claim 1 , wherein:

the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame wall and the outer frame includes a surface that that extends radially relative to the outer frame wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the outer frame,

the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly, and

the cushion frame and the cushion together at least partly form a breathing chamber.

11. A patient interface for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the patient interface comprising:

a cushion/frame sub-assembly including:

a cushion frame comprising a cushion frame material, the cushion frame having a cushion frame wall having an opening that extends along a cushion frame longitudinal axis; and

a cushion connected to the cushion frame, the cushion being adapted to form a seal with a patient's nose and/or mouth and including a cushion material that is more flexible than the cushion frame material;

an outer frame connected to the cushion/frame sub-assembly and configured to at least partly constrain the cushion/frame sub-assembly, the outer frame including:

an outer frame wall defining an opening that extends along an outer frame longitudinal axis;

at least first and second headgear attachment points; and

a portion engaged with an inlet conduit; and

headgear including one or more straps releasably attachable to the first and second attachment points of the outer frame,

wherein the outer frame is removably interlocked with the cushion/frame sub-assembly by aligning the cushion frame longitudinal axis with the outer frame longitudinal axis, and moving the cushion/frame sub-assembly and the outer frame towards one another until they reach an interlocked position in which the outer frame wall and the cushion frame wall are at least partially nested relative to one another.

12. The patient interface according to claim 11 , wherein the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame wall and the outer frame includes a surface that that extends radially relative to the outer frame wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the outer frame.

13. The patient interface according to claim 11 , wherein the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly.

14. The patient interface according to claim 11 , wherein the outer frame includes contact points to help prevent rotation of the cushion frame with respect to the outer frame.

15. The patient interface according to claim 11 , wherein the cushion frame and the cushion together at least partly form a breathing chamber around the patient's nose and/or mouth.

16. The patient interface according to claim 11 , wherein the cushion frame includes at least one protrusion, and the outer frame includes a perimeter frame member that engages the at least one protrusion.

17. The patient interface according to claim 11 , wherein the first and second headgear attachment points are adjacent to and on opposite lateral sides of the portion.

18. The patient interface according to claim 11 , wherein the cushion frame and the outer frame have complementary shapes.

19. The patient interface according to claim 11 , wherein:

the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame wall and the outer frame includes a surface that that extends radially relative to the outer frame wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the outer frame,

the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly,

the outer frame includes contact points to help prevent rotation of the cushion frame with respect to the outer frame, and

the cushion frame and the cushion together at least partly form a breathing chamber around the patient's nose and/or mouth.

20. A mask assembly for treatment of sleep disorder breathing by delivering a flow of pressurized gas to a patient, the mask assembly comprising:

a cushion/frame sub-assembly including:

a cushion frame comprising a cushion frame material, the cushion frame having a cushion frame annular wall defining a circular opening that extends along a cushion frame longitudinal axis; and

a cushion connected to the cushion frame, the cushion being adapted to form a seal with a patient's nose or nose and mouth and including a cushion material that is more flexible than the cushion frame material;

a skeleton frame to at least partly constrain the cushion/frame sub-assembly, the skeleton frame including:

a skeleton frame annular wall defining a circular opening that extends along a skeleton frame longitudinal axis:

at least first and second headgear attachment points; and

an annular portion adapted to engage an elbow or inlet conduit; and

headgear including at least first and second straps with clips, the clips being releasably attachable to the first and second attachment points of the skeleton frame,

wherein the skeleton frame is configured to be removably interlocked with the cushion/frame sub-assembly by aligning the cushion frame longitudinal axis with the skeleton frame longitudinal axis, and moving the cushion/frame sub-assembly and the skeleton frame towards one another until they reach an interlocked position in which the skeleton frame annular wall and the cushion frame annular wall are at least partially positioned in a common plane.

21. The mask assembly according to claim 20 , wherein the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame annular wall and the skeleton frame includes a surface that that extends radially relative to the skeleton frame annular wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the skeleton frame.

22. The mask assembly according to claim 20 , wherein the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly.

23. The mask assembly according to claim 20 , wherein the skeleton frame includes contact points to help prevent rotation of the cushion frame with respect to the skeleton frame.

24. The mask assembly according to claim 20 , wherein the cushion frame and the cushion together at least partly form a breathing chamber around the patient's nose and mouth.

25. The mask assembly according to claim 20 , wherein the cushion frame includes at least one protrusion, and the skeleton frame includes a perimeter frame member that engages the at least one protrusion.

26. The mask assembly according to claim 20 , wherein the first and second headgear attachment points are adjacent to and on opposite lateral sides of the annular portion.

27. The mask assembly according to claim 20 , wherein the cushion frame and the skeleton frame have complementary shapes.

28. The mask assembly according to claim 20 , wherein:

the cushion frame includes a ring shaped portion that extends radially relative to the cushion frame annular wall and the skeleton frame includes a surface that that extends radially relative to the skeleton frame annular wall, wherein in the interlocked position, a portion of the ring shaped portion engages the surface to help secure the cushion/frame sub-assembly to the skeleton frame,

the cushion frame and the cushion are integrally molded in one piece to provide the cushion/frame sub-assembly,

the skeleton frame includes contact points to help prevent rotation of the cushion frame with respect to the skeleton frame,

the cushion frame and the cushion together at least partly form a breathing chamber around the patient's nose and mouth,

the cushion frame includes at least one protrusion, and the skeleton frame includes a perimeter frame member that engages the at least one protrusion,

the first and second headgear attachment points are adjacent to and on opposite lateral sides of the annular portion, and

the cushion frame and the skeleton frame have complementary shapes.

29. The mask assembly according to claim 20 , wherein the skeleton frame annular wall, the first and second headgear attachment points, and the annular portion are formed as a one piece construction.

30. The mask assembly according to claim 20 , wherein the skeleton frame further comprises a main body extending radially away from the circular opening; the main body supporting the first and second headgear attachment points,

wherein the skeleton frame is snap-fit to the cushion/frame sub-assembly,

wherein the main body is positioned on an exterior side of the cushion frame,

wherein the annular portion engages the elbow, the annular portion having an inner wall and an inner layer positioned along the inner wall, the inner layer extending radially inward of the inner wall at an anterior side of the annular portion, the annular portion having a length along the skeleton frame longitudinal axis that is greater than a thickness of the main body, and

wherein the length of the annular portion is about equal to a length of the cushion frame annular wall.