Customized medical devices and apparel

• US 9,498,593 B2
• Filed: 12/10/2013
• Issued: 11/22/2016
• Est. Priority Date: 06/17/2013
• Status: Active Grant

• Current Assignee: Rem Sleep Medicine, PC
• Original Assignee: Metamason, Inc.
• Inventors: Karpas, Leslie Oliver, Moore, Robert William
• Primary Examiner(s): Matter, Kristen
• Application Number:
  US14/102,370
• Publication Number:
  US 20150157822A1
• Time in Patent Office: 1,078 Days
• Field of Search: 700/118, 700/98, 700/163, 703/1, 703/6
• US Class Current: 1/1
• CPC Class Codes: A61M 16/0605 Means for improving the adaptation of the mask to the patient
• CPC Class Codes: A61M 16/0666 Nasal cannulas or tubing devices for improving normal breathing through the nose A61F5/08; nose filters A62B23/06; outside holding devices A61M25/02
• CPC Class Codes: A61M 16/0683 Holding devices therefor
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 16/0875 Connecting tubes
• CPC Class Codes: A61M 2016/0661 with customised shape
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: B29C 33/52 soluble or fusible in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2995/0059 Degradable
• CPC Class Codes: B29K 2995/0062 water-soluble
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: G06T 17/00 Three dimensional [3D] modelling, e.g. data description of 3D objects
• CPC Class Codes: G06V 40/171 Local features and components; Facial parts eye characteristics G06V40/18; Occluding parts, e.g. glasses; Geometrical relationships
• CPC Class Codes: G06V 40/193 : Preprocessing; Feature extraction

Abstract

Systems and methods for making a custom sleep apnea mask or other wearable article are disclosed. The sleep apnea system comprises a face mask, a headband integrally connected to the face mask, and at least one air duct configured to direct air from the CPAP machine to nasal tubes. The face mask preferably comprises: an inner surface having the same shape as the user'"'"'s face; an upper surface configured to sit at a first predetermined distance between the user'"'"'s nose and eyes; and an outer surface configured to extend a second predetermined distance from the inner surface. Nearly shape and position of substantially all the surfaces of the mask are configured based on the shape and or location of facial features, resulting in a highly customized mask optimized for each individual patient.

Claims

1. A method of making a custom sleep apnea mask configured to operate with a CPAP machine, the method comprising:

scanning at least a portion of a user'"'"'s face;

generating a surface model of the user'"'"'s face;

identifying a set of facial features from the surface model, the set comprising;

a) a first point corresponding to the user'"'"'s nose, and

b) a second point corresponding to the user'"'"'s lips;

generating a first linear contour on the surface model based on the first point;

generating a second linear contour on the surface model based on the second point;

generating a third linear contour interposed between the first and second linear contours, wherein the third linear contour extends beyond the first point a determined offset;

generating an outer surface of the mask, wherein the outer surface comprises the first, second, and third linear contours; and

generating an inner surface of the mask, wherein the inner surface comprises at least a portion of the surface model between the first and second linear contours.

2. The method of claim 1, wherein the method further comprises:

providing a surface model of a head;

combining the surface model of the user'"'"'s face with the surface model of the head; and

wherein the generating of the inner surface of the mask is based on the combination of the surface model of the user'"'"'s face with the surface model of the head.

3. The method of claim 1, wherein generating the third contour comprises:

averaging the first contour and the second contour;

adding a lateral offset in a direction away from the surface model of the user'"'"'s face; and

low-pass filtering.

4. The method of claim 1, further comprising:

generating a surface model of nasal tubes;

orientating the surface model of the nasal tubes based on at least the first point; and

combining the surface model of the nasal tubes with the inner surface of the mask.

5. The method of claim 1, wherein the identifying of a set of facial features from the surface model comprises:

identifying a tip of the nose, a bridge of the nose between eyes, an upper-most point of a set of lips, an underside of the nose, a width of the face, and center points of two nostrils.