The present invention generally relates to customized apparel and, more specifically, customized CPAP Masks and related modeling algorithms.
Sleep apnea is a sleep disorder characterized by pauses in breathing or periods of shallow breathing during sleep. People affected by sleep apnea can experience sleepiness or feel tired during the day due to the disruptions to their normal sleep. Continuous positive airway pressure (“CPAP”) is a treatment option for obstructive sleep apnea. CPAP can be implemented as a positive airway pressure ventilator, which can apply air pressure on a continuous basis to keep the airways continuously open. Common implementations of CPAP therapy involve a nasal mask.
Customized CPAP masks and related modeling algorithms in accordance with embodiments of the invention are illustrated. One embodiment includes a method for generating a surface model of a CPAP mask, the method including obtaining facial scan data of a user's face, determining a set of landmark points from the facial scan data, wherein the set of landmark points relate to anatomical locations on the user's face, generating a base model, and deforming the base model into a deformed model using the set of landmark points.
In another embodiment, the method further includes generating a customized model by altering the deformed model using the facial scan data.
In a further embodiment, altering the deformed model includes performing a Boolean operation using the deformed model and a surface model generated using the facial scan data to alter an inner boundary surface of the deformed model such that the inner boundary surface of the deformed model can sit flush against the user's face.
In still another embodiment, the method further includes manufacturing the customized model using an additive manufacturing process.
In a still further embodiment, the method further includes generating a mold model based on the customized model.
In yet another embodiment, the base model is a rigged model including a plurality of joints that deforms the base model when moved.
In a yet further embodiment, deforming the base model includes moving at least one of the plurality of joints based on a predefined relationship with at least one of the set of landmark points.
In another additional embodiment, the base model is deformed in adherence to a set of constraints.
In a further additional embodiment, the base model includes an averaged model obtained from an aggregate database, wherein the averaged model is an average of stored facial scan data in the aggregate database.
In another embodiment again, the averaged model is an average of stored facial scan data of a selected demographic.
In a further embodiment again, further including determining a nasal curve from the facial scan data and altering nasal fittings of the deformed model to match the nasal curve.
In still yet another embodiment, determining a nasal curve includes manually determining the nasal curve.
In a still yet further embodiment, the deformed model includes a nasal interface including a single slit.
In still another additional embodiment, the deformed model includes a nasal interface including asymmetric nasal fittings.
In a still further additional embodiment, the asymmetric nasal fittings each includes a flange.
In still another embodiment again, obtaining facial scan data includes scanning the user's face using scanning technology.
In a still further embodiment again, obtaining facial scan data includes retrieving the facial scan data from a remote server.
In yet another additional embodiment, determining a set of landmark points includes manually determining the set of landmark points.
In a yet further additional embodiment, determining a set of landmark points includes using an algorithm and machine vision to automatically determine the set of landmark points.
Yet another embodiment again includes a customized CPAP mask including a customized mask comprising asymmetric nasal fittings and an inner boundary surface customized to sit flush with a face of a user, a tube frame connected to the customized mask, wherein the tube frame comprises slots for strap attachment, and a tube gasket connected to the tube frame, wherein the tube gasket is asymmetrical.
In a yet further embodiment again, the asymmetric nasal fittings includes a flange, wherein the flange is designed to expand when positive pressure is applied to the inside of the nasal fittings.
In another additional embodiment again, the customized mask further includes a gasket side, wherein the gasket side houses the connection point for the tube frame, and wherein the center perpendicular line of the gasket side crosses a specific distance above a top ear point of the user when the customized mask is worn by the user.
In a further additional embodiment again, the customized mask further includes a bottom surface, wherein the bottom surface meets the face of the user at a point between the user's upper lip and columella when the customized mask is worn by the user.
Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure.
The description and claims will be more fully understood with reference to the following figures and data graphs, which are presented as exemplary embodiments of the invention and should not be construed as a complete recitation of the scope of the invention.
Turning now to the drawings, customized CPAP masks and related modeling algorithms are illustrated. In many embodiments of the present invention, a CPAP mask customized to fit a specific face can be fabricated using a computer generated three-dimensional (“3D”) model and various manufacturing techniques. The 3D model can be generated using modeling algorithms that takes in facial scan data to create a mask model customized to a specific face of a user. In some embodiments, the modeling algorithm generates landmark points using facial scan data. These landmark points can be used in conjunction with a deformation bone system to alter a base shell model into a deformed model, which can then be used to form a customized mask model.
In some embodiments, a 3D model of a customized CPAP mask can be used in conjunction with manufacturing methods, such as but not limited to additive manufacturing processes, to fabricate a customized CPAP mask. In other embodiments, a 3D model of a customized CPAP mask is used to generate a 3D model of a CPAP mask mold, which can be fabricated using a variety of manufacturing methods, such as but not limited to additive manufacturing processes. A customized CPAP mask can be manufactured using the fabricated CPAP mask mold through a variety of manufacturing methods, such as but not limited to injection molding. Modeling algorithms to create 3D customized models of CPAP masks and different CPAP mask configurations are further described below.
A process 100 that can be utilized for generating a customized mask model in accordance with an embodiment of the invention is illustrated in
Once facial scan data is obtained, landmark points can be determined (104). Landmark points can be defined and determined in a number of different ways. In many embodiments, the landmark points are a set of points in 3D space that correlates with a surface model generated by the facial scan data. In some embodiments, landmark points are predefined to associate with anatomical locations on a face.
The process 100 can further include generating (106) a base model. In many embodiments, the base model is a surface model that is to be deformed. The base model can be generated in a number of different ways. In some embodiments, the base model can be dynamically generated from a database (108) that aggregates historical facial scan data. In further embodiments, the base model can be generated based on several variables, such as but not limited to demographic information of the person for which the CPAP mask is customized. In other embodiments, the base model is a constant, generic model generated from a data file that can be used for all situations. Methods of generating a base model are discussed in further detail below.
The base model can be deformed (110) into a deformed model. In many embodiments, the base model is deformed using determined landmark points. In further embodiments, the base model is a rigged model and is deformed using a deformation bone system (112). A rigged model can be defined as a 3D model bound to a digital skeleton that includes bones and joints. When the bones and joints are moved, the surface of the 3D model is deformed accordingly. In some embodiments, the base model is deformed to match a surface model generated from facial scan data. Methods of deforming a base model are discussed in further detail below. Once the deformed model is generated, a mask model customized to a face of a specific person can be generated. The customized mask model can be generated using the deformed model and facial scan data. In several embodiments, the deformed model is altered to match a surface model generated using facial scan data, ensuring that the customized mask model is tailored to a user's face. After generation of a customized mask model, the geometry of the model can optionally be verified (114) to ensure proper quality control. In many embodiments, the geometry of the model is automatically checked by a program to determine if the geometry meets certain constraint criteria. If the geometry check fails, a technician can verify (116) whether the failure is harmless. In other embodiments, the geometry is manually checked by a technician.
The process 100 can optionally include a manufacturing step. A customized mask model can be fabricated using a variety of different methods. In many embodiments, the customized mask model is converted into a 3D printer readable file, such as but not limited to STL files. The customized mask model can then be fabricated using an additive manufacturing process. In the exemplary embodiment shown in
Although a specific modeling algorithm is discussed above with respect to
In many embodiments, the bone deformation system is an automatic process where the quality of the end result depends on the quality of the base mask model. A base mask model can be generated using a number of different methods. In several embodiments, a static, generic base model is used for all cases. In many embodiments, an aggregate database is kept of all past facial scan data. The facial scan data can contain attributes that describes information concerning the user to which the scan data belongs. For example, in some embodiments, the aggregate database contains facial scan data that are classified by a number of different demographic information, such as but not limited to age, gender, and ethnicity. Using such a database, a base mask model can be generated to target a user's demographic.
In many embodiments, the aggregate database stores a base mask model that is the average of previous facial scan data. The base mask model can be updated as new facial scan data is entered. In some embodiments, a number of different mask models is stored in the aggregate database. The different base mask models can represent different categories of masks based on any of a number of factors, such as but not limited to age, gender, and ethnicity. In several embodiments, the different base mask models can represent different categories of face shape. The database can aggregate information and determine different criteria groupings and deviations of landmark points among users. Analyzing the deviation among landmarks across different user groups can provide information on when to create a new base mask model.
Although the discussions above relate to specific implementations of generating base mask models, a person having ordinary skill in the art would appreciate that the implementations described above can be altered to fit certain requirements of a given application. For example, the aggregate database can aggregate facial scan data to store surface models of a user's face instead of base mask models as described above.
Mask Model Deformation
A base mask model can be deformed based on landmark points determined from facial scan data.
Although mask deformation is described above with respect to methods of deforming mask models, a person having ordinary skill in the art would appreciate that the discussions above also applies to customized masks with features crafted from deformation constraints. As such, various embodiments of the invention are directed towards masks having features related to deformation constraints. For example, in some embodiments, a customized CPAP mask can have a gasket side angle such that the perpendicular center line crosses a specific distance above a specific ear of a user.
The mask model can also be altered using facial scan data. In many embodiments, facial scan data are used to produce a surface model of a user's face in order to customize the mask model for the user's face. In some embodiments, a Boolean operation is performed on a mask model and a surface model of a user's face to alter the mask model such that the mask model will sit flush against the user's face.
One aspect of CPAP masks is how well the nasal fittings fit in a user's nostrils. Customized CPAP masks in accordance with many embodiments of the invention can be designed to incorporate nasal fittings that are customized to fit a user's nostrils. There are many methods to design customized nasal fittings. In some embodiments, the mask models are automatically altered to incorporate customized nasal fittings using photographic images, facial scan data, and/or surface models. A curve tracing algorithm can determine nostril curves using the aforementioned assets and alter the mask model accordingly. In other embodiments, incorporating customized nasal fittings is manually shaped using photographic images, facial scan data, and/or surface models.
Nasal fittings can be designed to incorporate any shape, including but not limited to irregular shapes and asymmetric shapes. The nasal fittings can also be asymmetrical in the sense that the left and right nasal fittings can differ from one another for a single user.
Nasal fittings in accordance with many embodiments of the invention can be designed to incorporate features that assist in providing a secure fit to the user's nostrils. Nasal fittings can be designed to include flanges that help prevent the nasal fittings from dislodging once seated inside the user's nostrils.
Nasal fittings can have different widths for a custom fit for a particular user. In many embodiments, the nasal interface can be designed as a single slit, shown in
Although nasal fittings are described above with respect to methods of modeling nasal curves, a person having ordinary skill in the art would appreciate that the discussions above also applies to customized masks with nasal fittings formed through the modeling methods above. As such, various embodiments of the invention are directed towards masks having nasal fittings with contours to match a specific user's nostril shapes.
Customized CPAP masks in accordance with embodiments of the invention can be adapted into different configurations. The customized CPAP masks can be designed and manufactured to be readily incorporated into current CPAP ventilation systems.
Although specific CPAP masks and related mask modeling algorithms, many different mask configurations and modeling algorithms can be implemented in accordance with many different embodiments of the invention. It is therefore to be understood that the present invention may be practiced in ways other than specifically described, without departing from the scope and spirit of the present invention. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents.
The current application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62/373,866 entitled “CPAP Mask Algorithms” filed Aug. 11, 2016. The disclosure of U.S. Provisional Patent Application No. 62/373,866 is hereby incorporated by reference in its entirety for all purposes.
Number | Date | Country | |
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62373866 | Aug 2016 | US |