CN106999742B - Kiosk for customizing a facial breathing mask - Google Patents

Abstract

The apparatus and associated methods relate to semi-custom facial breathing masks having selectively removable material that, when removed, alters one or more facial fit dimensions to provide a more customized or personalized fit to the wearer's face. In an illustrative embodiment, a facial breathing mask may be customized based on a facial size determined using image data corresponding to a wearer's face. In some embodiments, the mask customization module may modify the shape and/or size of the facial respiratory mask. For example, the processor may select an optimal mask blank from the different mask blanks that corresponds to the image data corresponding to the wearer's face. The processor may determine a customization operation to perform on the selected mask blank based on the image data and the selected mask blank. Some embodiments may provide mask customization based on personal preferences. The system may advantageously provide the wearer with an optimally fitted mask and/or a personally customized mask.

Description

Kiosk for customizing a facial breathing mask

Cross Reference to Related Applications

This application is a PCT application claiming priority of a co-pending U.S. provisional patent application serial No.62/015,249 entitled "Customizing Facial Breathing Masks Based on Facial image Data" filed on 20/6/2014, which is incorporated herein by reference for all purposes as if reproduced in its entirety.

To the extent that the disclosure of the following previously filed applications is not inconsistent or directly inconsistent with this disclosure, this application also incorporates by reference the disclosure of the following previously filed applications in their entireties:

13/839,056 System and Method for Selecting a respiratory organ, 3 months and 15 days 2013

13/839,186 System and Method for Selecting a respiratory organ, 3 months and 15 days 2013

61/814,897 System and Method for Selecting PPE, 4 months and 23 days 2013

61/814,905 System and Method for Evaluating PPE Fit, 4 months and 23 days 2013

61/861,294 Virtual Mask fixing System, 8.1.2013

61/917,171, Virtual Mass Alignment for Fit Analysis, 12.2013, 17.

PCT/US2014/024098, Virtual Mass Alignment for Fit Analysis, 3/12/2014

Technical Field

Various embodiments are generally directed to customizing a facial respiratory mask based on image data corresponding to a person's face, for example, where such customization may occur in real-time and/or in situ.

Background

Hazardous breathing environments may arise in certain work environments. For example, cutting gypsum board may generate fine dust when building a new home. Such fine dust can be dangerous if inhaled by workers. When sawing wood, sawdust can be a by-product of the operation. When texturing a ceiling, particles may be generated. And when painting walls and/or ceilings, paint droplets may be generated and enter the atmosphere. Newly laid carpets may release fibers into the air. Also, old buildings may have asbestos, which may enter the air if careless.

Respiratory masks have been widely used in hazardous and/or potentially hazardous environments. Such masks have been used in the generation of particles. Breathing masks may also be used if there are hazardous chemicals in the atmosphere. Some air masks may have chemical agents to neutralize toxic gases. Some respiratory masks may be coupled to a safe source of breathable air. Some respiratory masks may be connected to a portable canister of breathable air.

Many industrial operations can cause air pollution by generating and injecting pollutants into the atmosphere. The combustion of coal or other materials may generate particulates in the atmosphere. Chemical companies may produce chemical vapors that may be released into the atmosphere. Additionally, some metropolitan centers have dangerous air pollution levels at certain times and/or seasons. In such metropolitan centers, many people may be exposed to these polluted atmospheres. Thus, there may be a need for additional, non-industrial users to have easy access to respiratory masks. In the past, respiratory masks have typically been sold as is; but as more non-traditional (e.g., non-industrial) users begin to use masks, there may be a need to provide more customized respiratory masks in non-industrial settings.

Disclosure of Invention

This may be useful for providing a custom or semi-custom respiratory mask given various divisions of the customer (e.g., with respect to age, gender, region, facial type, personal and/or aesthetic preferences, mask decoration needs, etc.). And in some settings (e.g., in crowded areas such as subway stations or areas with poor air quality), it may be useful to provide semi-custom respiratory masks that are available in real-time and/or on-site (e.g., via a kiosk or vending machine). Such semi-custom respiratory mask kiosks/vending machines may be capable of providing custom masks by scanning a user's face (e.g., to capture facial image data and/or critical dimensions of the user's face (e.g., by scanning or taking a picture)), e.g., allowing for automatic selection of an appropriate mask blank (typically from mask blanks available within a field device) and/or automatic formation of a selected mask blank based on facial measurements of an individual user. A premium kiosk device may even be able to offer further customization options, for example, with respect to other features such as a respiratory mask. Thus, an individualized/personalized/customized mask may be provided in real-time (e.g., immediately) at a desired location. As masks become more common, providing semi-custom masks of this type may become particularly useful, for example, for use by typical customers engaged in their normal daily lives in urban centers with air quality/pollution concerns, as real-time, in-place delivery of semi-custom masks may better address such non-industrial user needs (e.g., provide better delivery systems for non-industrial users).

Apparatus (e.g., vending machine or kiosk) and associated method embodiments may relate to a facial breathing mask having a selectively removable material that, when removed, may alter one or more facial fit dimensions to provide a customized fit to a wearer's face. In an illustrative embodiment, a facial breathing mask may be customized based on a facial size determined using image data corresponding to a wearer's face. In some embodiments, the mask customization module may modify the shape and/or size of the facial respiratory mask. The processor may select an optimal mask blank corresponding to image data corresponding to the wearer's face from among the different mask blanks. The processor may determine a customization operation to perform on the selected mask blank based on the image data and the selected mask blank. Some embodiments may provide mask customization based on personal preferences. Device or system embodiments may advantageously provide a best-fit mask and/or a personally customized (e.g., semi-customized) mask for the wearer. And beneficially, in some embodiments, such customized masks may be provided in situ and/or in real time.

Various disclosed embodiments may realize one or more advantages. In some embodiments, the quality of the exhalation may be improved, for example, by selecting the valve type, number, and/or orientation. For example, some embodiments may provide a mask that best fits a wearer with many different facial geometries. In some embodiments, the system may recommend a style of respiratory mask to the wearer based on facial image data of the wearer. Such a system can quickly provide a custom fit respiratory mask. Custom fitted masks may improve wearer compliance (compliance) with the use of a respiratory mask. Various embodiments may improve the quality of the seal of the mask to the wearer's face. A mask with a good face seal may provide better protection against the hazardous outside atmosphere. Various embodiments may help express the personal identity and preferences of the wearer. For example, the wearer may select a mask of a preferred style and/or color and/or a fragrance for the mask. Various embodiments may improve the health of the wearer by providing a selection of filter materials to protect against different environmental hazards (e.g., based on hazards at the point of purchase and/or user input regarding possible exposure). A respiratory mask that provides better protection may advantageously save lives and/or improve health. Embodiments may allow semi-custom mask delivery at or near the site of exposure and/or the site requiring protection (e.g., where contamination is experienced or expected to be experienced), and/or at the point of purchase, and these semi-custom masks may typically be provided in real time (e.g., immediately during immediate customization or with minimal delay). Thus, better mask/protection may be available where and when needed. The provision of such semi-custom real-time respiratory masks may be particularly useful in non-industrial settings and/or for non-industrial users.

The details of various embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

Drawings

Fig. 1 depicts an exemplary process for customizing a respiratory mask for a user based on optical image data.

Fig. 2A-2C depict exemplary facial dimensions that may be used to customize a respiratory mask.

Fig. 3A-3C depict an exemplary flat-fold dust mask.

Fig. 4A-4B depict an exemplary cup-shaped dust mask.

Fig. 5 depicts an exemplary respiratory mask with an exemplary nose clip.

Fig. 6A-6B depict an exemplary respiratory mask without a nose clip.

Fig. 7A-7C depict an exemplary respiratory mask with an exemplary exhalation valve.

Fig. 8A-8B depict an exemplary respiratory mask without an exhalation valve.

Fig. 9A depicts a block diagram of an exemplary mask customization system.

Fig. 9B depicts a block diagram of an exemplary mask modification (e.g., semi-custom) module.

Fig. 9C depicts a block diagram of an alternative exemplary mask modification (e.g., semi-custom) module.

Fig. 9D depicts a more detailed block diagram of an exemplary mask modification (e.g., semi-custom) module.

FIG. 10 depicts a flow chart depicting an exemplary method of deriving a facial metric from image data.

Fig. 11 depicts a flow chart describing an exemplary method of selecting a mask for use for customization.

FIG. 12 depicts a flow chart describing an exemplary method for customizing a mask for a user.

Like reference symbols in the various drawings indicate like elements.

Detailed Description

It should be understood at the outset that although an illustrative implementation of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definitions of terms shall apply throughout the application:

the term "comprising" means including, but not limited to, and should be interpreted in the manner in which it is typically used in the patent context;

the phrases "in one embodiment" and "according to one embodiment" or the like generally mean that a particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the invention, and may be included in more than one embodiment of the invention (importantly, such phrases do not necessarily refer to the same embodiment);

if the specification describes something as "exemplary" or "an example," it is understood that reference is made to a non-exclusive example;

the terms "about" or "approximately" or the like, when used with a number, can mean a particular number, or alternatively, a range close to a particular number, as understood by those skilled in the art (e.g., +/-10%); and

if the specification states a component or feature "may", "can", "might", "should", "will", "preferably", "possible", "typically", "optionally", "for example", "often", or "possible" (or other such language) to be included or to have a property, that particular component or feature is not required to be included or to have that property. Such components or features may optionally be included in some embodiments, or they may be excluded (with both options being supported for the purpose of claim).

To aid understanding, this document is organized as follows. First, an exemplary custom mask vending machine (or kiosk) is briefly described with reference to fig. 1. 2A-2C, various facial sizes that may be used in an exemplary mask customization system are described. 3A-8B, discussion turns to exemplary embodiments of a customizable respiratory mask illustrating various customization features. In particular, different types and styles of respiratory masks will be described. A block diagram of an exemplary mask customization system is then described with reference to fig. 9A-D. Referring to fig. 10-12, an exemplary method for use in a mask customization system is described. Finally, additional embodiments are described in language dependent on the claims.

Fig. 1 depicts an exemplary process of customizing a respiratory mask for a user based on optical (facial) image data. In the depiction of fig. 1, a crowd 100 waits in line or queue at a customizable mask vending machine (or kiosk) 105. The customizable mask vending machine 105 has a user input device 110 against which a purchaser (or user) 115 selects a mask design for the user input device 110. The customizable mask vending machine 105 may have a camera (and/or 3D scanner or other imager capture device) that is utilized to obtain facial image data of the purchaser 115. The customizable mask vending machine 105 may use facial image data obtained via a camera (and/or 3D scanner, etc.) to customize a mask blank corresponding to a user's selected mask design. For example, the vending machine 105 may instruct the person/user for proper positioning (e.g., which direction and/or distance from the camera to face), and then automatically take a picture of the user (or otherwise scan the user's face) to capture an image of the user's face, and provide the face image data for use in creating a customized mask. For example, the customizable mask vending machine 105 may compare facial image (and/or 3D model) data to mask geometry data to determine how to customize the mask blank to best fit the purchaser's face. For example, the facial image data may allow the vending machine to select the best mask blank based on which of five basic facial types (which most closely correspond to the individual facial image data). The population 100 may have various facial geometries and sizes 120. The customizable mask vending machine may use one or more facial size metrics calculated from the facial image data and/or one or more corresponding metrics of the selected mask blank to determine the customization operation. The customizable mask vending machine may then add material, remove material, and/or shape the mask blank corresponding to the determined customization operations 125. The customizable mask vending machine 105 may accomplish customization by decorating the customized mask blank in response to the mask design selected by the user (although in other embodiments, the decoration stage may be performed earlier in the process). The customizable mask vending machine 105 may then receive payment and deliver the customized mask 130 to the purchaser (although in other embodiments, the payment phase may occur earlier in the process, e.g., before mask customization occurs). The purchaser may advantageously obtain a well-fitting mask 130 having his/her preferred design pattern (e.g., a semi-custom mask that is more likely to provide effective protection). Additionally, the user/purchaser may be able to obtain the desired (semi-customized) mask on-site (e.g., without having to visit a store) and/or in real-time.

Fig. 2A-2C depict exemplary facial dimensions that may be used to customize a respiratory mask. In fig. 2A, a front view of a person's face 200 includes dimensions that may be used in creating a well-fitting custom respiratory mask. Labeled on the face of the person is a zygomatic width dimension 205. The zygomatic width dimension 205 may be substantially the width of the user's face from cheek bone to cheek bone. Also labeled on the human face is a mandible angular width dimension 210. The mandibular angular width 210 dimension may be substantially the width of the user's face as measured from jaw to jaw. It is also noted on the nose width 215 of the person's nose 220. Finally, the lip length 225 of the person's lips 230 is depicted. The vending machine may measure and use one or more of these face sizes.

In fig. 2B, a side view of person 200 includes further dimensions that may be used in creating a well-fitting custom respiratory mask. Labeled on this figure is the subnasal point-nasal bridge point length 235. The nose protrusion distance 240 is also noted. The submental-nasal bridge point length 245 may be substantially the vertical distance of the human face 200 from the bottom of the chin 250 to the nasal bridge 255. Finally, the submental-subnasal length 255 may be substantially the vertical distance of the human face 200 from the bottom of the chin 250 to the bottom of the nose 220.

In fig. 2C, the side view of person 200 includes further dimensions that may optionally be used in creating a well-fitting custom respiratory mask. The depth 260 of the face size is labeled on the figure. Tragus-subpinal arc length 265 and tragus-subpinal arc length 270 are also labeled. Other key facial dimensions may be used in determining the customization for the mask or mask blank. One or more facial sizes may be used in creating a custom respiratory mask. In some mask customization systems, for example, the sealing surface may be made to conform to the face of the user. For example, the sealing surface may define the nose and/or mouth of the user. In some embodiments, material may be added to the mask blank to ensure a complete mask/skin interface. In an exemplary embodiment, material may be subtracted from the mask blank to ensure a complete mask/skin interface. In some embodiments, the mask blank may be shaped (e.g., cut filter material) and/or formed to form a complete mask/skin interface.

Fig. 3A-3C depict an exemplary flat-fold dust mask. In fig. 3A, an exemplary flat-fold face mask 300 is depicted in a folded position. For example, the flat-fold mask 300 may be unfolded when worn by a wearer. In fig. 3B, a front perspective view of the open flat-folded face mask 305 is depicted. When opened, the flat-fold mask can engage the face of the wearer. In fig. 3C, a wearer 310 is depicted wearing an exemplary flat-fold face mask 315. In the depicted embodiment, the flat-fold mask 315 extends perpendicularly from a nasal bridge region 320 of the wearer 310 to a chin region 325 of the wearer 310. And the exemplary flat-fold mask extends horizontally from the left cheek portion 330 to the right cheek portion 335 of the wearer 310. In this manner, the breathable mask completely encloses the nose and mouth of the wearer. Such an enclosure may ensure that air in the external atmosphere must traverse the respiratory mask before being inhaled by the wearer 310.

Fig. 4A-4B depict an exemplary cup-shaped dust mask. In fig. 4A, an exemplary cup-shaped respiratory mask 400 is depicted from a perspective view. Fig. 4B depicts an exemplary cup-shaped respiratory mask 405 being worn by a wearer 410. In the depiction of fig. 4B, the mask again completely covers the wearer's mouth and nose. The respiratory mask is depicted as being secured by straps that pass through the transition behind the head and/or neck of the wearer 410 and connect to both the left and right sides of the respiratory mask.

Fig. 5 depicts an exemplary respiratory mask with an exemplary nose clip. In the embodiment of fig. 5, the exemplary respiratory mask 500 is depicted from a perspective view. The exemplary respiratory mask 500 includes a nose clip 505. In some embodiments, the nose clip may be deformable. For example, a deformable nose clip may help provide a custom seal around a portion of a wearer's nose. The nose clip itself may be customizable. For example, in some embodiments, the nose clip can be made longer or shorter, or the user can select from a variety of sizes and/or shapes and/or materials of nose clip blanks. In some embodiments, the nose clip may be customizable and still deformable. In an exemplary embodiment, the nose clip can be custom formed to correspond to the nasal bridge region of the wearer's face. In some embodiments, the nose clip may be detachable from the mask. In some embodiments, a nose clip may be coupled to the respiratory mask.

Fig. 6A-6B depict an exemplary respiratory mask without a nose clip. In the embodiment of fig. 6A, an exemplary respiratory mask 600 is depicted without a nose clip. In the depicted embodiment, the respiratory mask 600 may be secured to the wearer's face by coupling each of two ear straps 605 around the wearer's ears (although in other embodiments, a headband or other means for attaching in place on the user's face/head may be used). For example, ear band 605 can comprise an elastomer. In some embodiments, ear band 605 may be customizable. For example, the ear band (or headband) 605 may have a customized length. The customization system may customize the length to correspond to the size of the wearer's face. In some embodiments, for example, the strength of the elastomer may be customized based on a user's selection. The depicted respiratory mask 600 includes a filtering portion 610. For example, the size of the filter portion 610 may be customizable. In some embodiments, the type of filter material may be customizable. For example, various types of filter materials may be selected by the wearer (e.g., where different available mask blanks have different filtering capabilities (e.g., typically due to different filter materials, such that selection of a mask blank may result in selection of a particular filter material)). In some embodiments, the filter material may be determined by a custom system to correspond to a particular atmospheric hazard. The user may also select from different combinations of filter materials. For example, different filter materials may provide different levels of protection.

In fig. 6B, the respiratory mask 615 may have a customizable sealing surface. The sealing surface height may be customizable around the sealing perimeter. For example, the sealing surface may provide a complete seal circumferentially around the mouth and nose of the wearer. The three-dimensional facial height data may be used to customize the sealing surface of the respiratory mask 615. Such three-dimensional height data may be obtained, for example, by various three-dimensional imaging techniques described in "Virtual Mask Alignment for Fit Analysis" (PCT/US 2014/024098). For example, an exemplary method for obtaining such three-dimensional facial height data is described with reference to at least paragraphs [0054, 0065 and 0081-0082] in patent application PCT/US2014/024098 entitled "Virtual Mask Alignment for Fit Analysis," filed 3, 12, 2014 (the entire disclosure of which is incorporated herein by reference), and FIG. 1.

Fig. 7A-7C depict an exemplary respiratory mask with an exemplary exhalation valve. In fig. 7A, an exemplary respiratory mask 700 is depicted with an exemplary exhalation valve 705. The exhalation valve 705 may provide one-way fluid (e.g., air) delivery from the interior side of the respiratory mask to the exterior side of the respiratory mask (while preventing external unfiltered air from entering through the valve). Such an exhalation valve 705 may facilitate exhalation by a user, for example. For example, exhalation valve 705 may reduce the resistance to exhalation that filtering may otherwise impart to the user. Exhalation valve 705 may direct exhaled gas in a preferred direction. For example, exhalation valve 705 may direct exhaled air away from the wearer's eyes. Such a preferred orientation may, for example, minimize the likelihood of moisture in the exhaled air condensing on the wearer's eyewear. The shape of the exhalation valve 705 may be customizable and/or selectable. In some embodiments, the preferred direction may be customizable. In some embodiments, the exhalation resistance may be customizable. In an exemplary embodiment, the user may select two or more exhalation valves, for example, one on either side of the user's face. For example, the aperture size may be customizable. In some embodiments, the spring constant of the unidirectional control apparatus may be customizable. And in some embodiments, the position of the exhalation valve on the mask may be customizable (e.g., where the user selects based on preferences).

In fig. 7B, an exemplary customizable mask 710 is depicted in a perspective view. The customizable mask 710 has an exhalation member 715 coupled to the respiratory mask 710. For example, the exhalation cap 715 may be selectively attached to the respiratory mask 710 based on a user's selection. The mask customization system may provide a complete seal between the exhalation cap 715 and the respiratory mask 710 during customization. In fig. 7C, another exemplary respiratory mask 720 is depicted with an exemplary exhalation valve 725. For example, exhalation valve 725 may have a rigid or semi-rigid member 730, and rigid or semi-rigid member 730 may help maintain the shape of the mask.

Fig. 8A-8B depict an exemplary respiratory mask without an exhalation valve. In the embodiment of fig. 8A-8B, the exemplary respiratory masks 800, 805 do not have exhalation valves. In some embodiments, other attachments may be customizable to connect to the respiratory mask. For example, in some embodiments, chemical agents may be attached to the respiratory mask (e.g., where a kiosk automatically sprays chemicals onto selected mask blanks or where some mask blanks are pre-treated with chemicals, or where a kiosk attaches pre-treated sheets of material to mask blanks, for example). In some embodiments, the user may select an air hose coupling device to be attached to the mask. In such embodiments, the air hose coupling may allow a supply of safe breathing air to be coupled to the respiratory mask. In some embodiments, a fragrance (which may be a perfume or aroma) may be sprayed into the mask, for example, based on user preferences.

Fig. 9A depicts a block diagram of an exemplary mask customization system (e.g., a kiosk or photo kiosk or vending machine device). In the embodiment of fig. 9A, a block diagram 900 of an exemplary mask customization system is shown coupled to an imaging kiosk vending machine 905 (e.g., a kiosk). The imaging kiosk vending machine 905 may have a camera 910 (or other image capture device) for obtaining facial image data corresponding to a user. The display device 915 may optionally display the captured face image data. For example, the display device may allow a user to make inputs using a touch sensitive screen (although in other embodiments, user inputs to the vending machine may be made using a keyboard, voice recognition, or other data entry means). In some embodiments, the display 915 may provide instructions to the user. For example, the display screen 915 may provide instructions directing the user to turn the user's face to the side for side view image capture. In some embodiments, for example, the display screen 915 may guide the user to stand and/or sit in a particular position and/or change orientation (e.g., facing direction). The kiosk/vending machine/photo booth may have a credit card reader to obtain financial transaction information from the user. In some embodiments, the photo kiosk 905 may also have a mask modification module 920 for performing mask customization operations. The camera kiosk 905 may include a mask delivery port 925 where a customized mask is delivered to the user.

In fig. 9A, block diagram 900 may represent, for example, a mask optimization control module. The mask optimization control module 900 may include, for example, a processor 930 electrically coupled to a photo kiosk (or kiosk) 905 via an input/output port 935. The processor 930 may be in communication with the mask modification module 920, the camera 910, and/or the display device 915. Processor 930 may send a signal corresponding to a display instruction for the user. Processor 930 may receive user input, for example, from touch-sensitive display 915. Processor 930 may send instructions to operate camera 910. The processor may receive image data from the camera 910. The processor may send instructions to the mask modification module 920. For example, after receiving image data from camera 910, processor 930 may send the image data to memory 940. Processor 930 may perform operations to determine a face size from the image data. Processor 930 may store the determined face size in memory 945 and/or retrieve the determined face size from memory 945. Processor 930 may retrieve mask (blank) data from mask database 950. The processor 930 may send the image and/or mask data to the mask selection module 955. The mask selection module 955 may select a mask (blank) based on data sent to the mask selection module 955. Processor 930 may send the image and mask data to mask customization calculator 960. The mask customization calculator 960 may determine the customization operation based on data sent to the mask customization calculator 960. The processor 930 may send signals/instructions corresponding to the determined mask customization operation to the mask modification module 920 of the photo kiosk 905. Processor 930 may, for example, send signals/instructions corresponding to the mask decoration selected by the user to mask decoration module 965.

Thus, a typical mask customization system (e.g., of the type that may be found in a point of purchase or point of need vending machine, operable to provide a semi-customized mask to better fit the needs of a particular user) may typically include a processor (or computer), a camera or other image scanner (e.g., an image capture device), and a mask modification module operable to physically modify/customize a mask blank or template according to instructions from the processor or computer. Typically, the processor will receive facial image data from a camera (e.g., an image capture device), will process the facial image data to generate mask modification or customization instructions, and then send those instructions to a mask modification module, which will automatically operate according to the instructions to convert the mask blank into a semi-customized mask. Typically, the system may also include an external housing (similar to a vending machine or photo kiosk) that will house the camera and mask modification module, and in some embodiments may also house the processor (although in other embodiments the processor may be remotely located, and the housing may instead include a communication module (such as a wireless transmitter/receiver) that allows communication with the processor (e.g., sending camera facial image data to the processor, and then receiving instructions from the processor to then be provided to the mask modification module)). Some embodiments may also include an input device (e.g., operable to allow a user to input user preferences (which may then contribute to selecting a mask blank or generating mask modification instructions) and/or payment information (such as a credit card reader)) and/or an output device (e.g., for providing instructions to the user, e.g., regarding orientation with respect to the camera). An exemplary input device may be a keyboard or a touch screen or speech recognition, and an exemplary output device may be a display screen and/or a speaker. Typically, the processor may receive preferences or other user input data from an input device, and the processor may send instructions to the user (e.g., for interacting with the camera) via an output device.

Once the processor has used user input (e.g., regarding mask preferences) and/or facial image data (e.g., facial measurements) to select mask blanks (typically selected from a plurality of mask blanks of various sizes, shapes, filtering capabilities, etc.) and generate and transmit mask modification or customization instructions to the mask modification module, the mask modification module will automatically operate (e.g., select the selected mask blank and apply one or more modification techniques to the mask blank, typically in accordance with those instructions (e.g., in an automated manner) to form a semi-customized mask in accordance with instructions from the processor). Depending on the particular semi-custom mask vending machine (e.g., kiosk) embodiment, the amount of available mask modifications (and mask blank selectivity) may vary. For example, fig. 9B illustrates a basic mask modification module in which mask blanks are selected from one or more (and typically a plurality of) frames 921B, where each frame has a different mask blank (e.g., different in size, shape, type (flat versus molded), filtering capability and/or (attached at the front) features/elements (such as nose clip, head attachment system (e.g., straps), exhalation valve, decorative cover, fragrance and/or sealing section material or thickness)) than the other frames (and typically each frame will have a plurality of identical mask blanks, e.g., at least 10 specific mask blanks in each frame), and then modified by cutting using cutting element 926B. Thus, in fig. 9B, mask modification module 920B includes a plurality of racks 921B (each housing a plurality of different mask blanks), a delivery mechanism 922B (operable to deliver selected mask blanks from the racks to a cutting element), a cutting element 926B (operable to cut mask blanks on command to provide a better (semi-custom) fit for a user (e.g., by cutting or trimming the edges of the mask blanks), and a dispensing element 929B (which may be part of the delivery mechanism), the dispensing element 929B operable to dispense a completed semi-custom mask to a user The module will typically only cut or shape the mask blank, so the various mask blanks will typically have any features or elements already attached to the initial mask blank (such as straps, sealing section material, exhalation valves and/or nose clips), the initial mask blank is loaded into a rack (e.g., having multiple racks, where each rack has multiple identical mask blank types, and each rack has a different mask blank type (e.g., a mask blank having a differently sized and/or shaped, and/or having different features or elements pre-attached, and/or having different mask blank categories (e.g., flat folded and molded cup)). typically, in the embodiment of fig. 9B, straps will be attached at locations on the mask blank to ensure that they will not be cut out during the mask modification process, and the seal segment material will be pre-attached and then will be configured by cutting the mask blank (e.g., cutting both the filter material and the seal segment of the mask blank in a single step).

While the basic mask modification module of fig. 9B will be able to provide an effective semi-custom mask to a user at a desired time and/or location, some mask modification module embodiments may provide even more customization. Fig. 9C illustrates an advanced (premium) mask modification module 920C that may allow further mask customization for a particular user's preferences and/or needs and/or face. For example, the mask modification module 920C of fig. 9C includes one or more (and typically a plurality of) racks 921C (where each such rack typically holds a plurality of specific mask blanks, and each rack has a different mask blank than the other racks), a heating die 923C (which may form and/or configure the mask blanks), a cutting element 926C (operable to cut the mask blanks according to instructions from the processor), and an attachment device 927C (operable to attach one or more elements or features to the mask), it will typically work in conjunction with a storage unit for each of the various elements or features that may optionally be attached to the mask (e.g., strap S, nose clip N, exhalation valve V, trim cover D, and/or sealing foam or other sealing material F). Additionally, mask modification module 920 of fig. 9C may also typically include a delivery mechanism or system 922C (operable to move mask blanks within the module, e.g., from the frame to the die to a cutting device and/or to an attachment device), which may also include a dispensing element 929C (for dispensing masks to a user, although in some embodiments the dispensing element may be a separate element). In some embodiments, the cutting/shaping and attachment may occur at the same location, for example where a robotic arm brings various equipment to the mask blank at a single location/workstation (such that there may not be any delivery system, or the delivery system may only move the mask blank from the rack to a single station and/or from the station for dispensing into a slot, for example, for pickup by a user). Any or all of the portions of automated mask modification module 920c may be used to automatically create a semi-custom mask, depending on instructions from the processor.

Fig. 9D illustrates an exemplary (advanced) mask modification module 920D in more detail. In fig. 9D, the delivery system includes one or more conveyor belts 922D, the conveyor belts 922D operable to move mask blanks selected or dispensed from the rack 921D (and typically there may be multiple racks from which mask blanks are selected) between stations (although in other embodiments there may be no need for delivery between stations, e.g., where mask blanks reside in one location/station during formation (e.g., formation and attachment) and different robotic arms (or a single robotic arm capable of multiple functions) perform various required modifications). An optional heating die 923d (which may help form/configure the facepiece in some embodiments) may include a robotic arm to help divert the facepiece blank between conveyor belts. And in some embodiments, there may be multiple dies 923d, with a particular die being automatically selected for a particular mask forming process based on instructions from the processor. A cutting device (such as a laser or cutting blade) 926d may automatically modify the mask blank (e.g., cutting the edge to better fit the contours of the user's face and/or cutting the hole for attaching the exhalation valve) according to instructions from the processor, and an attachment device (such as, for example, an adhesive applicator or ultrasonic welder or stapler) 927d may then automatically attach one or more elements (such as straps, etc.) to the mask blank. In fig. 9D, the attachment device would be located on the robotic arm and would include an integrated tape feed mechanism (e.g., automatically dispensing tape from a reel proximate to the attachment device, such as an adhesive applicator and/or (ultrasonic) welder and/or stapler) for attaching the tape in a single step. The end of the conveyor belt system 922d can then be used as a dispensing element 929d (e.g., dropping the completed mask via gravity to a pick-up hopper/chute 925 d).

The skilled person will appreciate that when using a basic mask modification module (such as, for example, the module shown in fig. 9B), the mask blank typically may start more completely (e.g. already having a strip attached at a location that will not be cut during the mask modification process, and/or already having a nose clip attached, and/or already having an exhalation valve attached, and/or already having a sealing section of sealing material (attached around the edge of the mask blank), such as foam (so that only the excess sealing section may be cut away from the mask blank during customisation)). In other words, the base mask-modifying module may have one or more elements/features pre-attached to various mask blanks. In addition, the chassis may hold mask blanks having different levels of filtering. In more advanced models (such as the model shown in fig. 9C), the initial mask blank in the frame may be more basic (e.g., not having an attached strap, nose clip, valve, trim cover, and/or sealing material in the initial instance, but rather adding specific features or elements during mask modification (e.g., semi-custom processing) to provide a more customized mask). In some embodiments, the mask blank may vary only by filtration level or material, size, shape, and/or type/category (e.g., flat folded or molded cup-shaped), and may not have any other pre-attached features (possibly in addition to the seal section material in some embodiments). Some embodiments may initially have only a flat mask blank, and use a heated mold if a molded cup-shaped mask is desired, although other embodiments may have a frame with both flat and molded cup-shaped mask blanks. Additionally, some embodiments may allow a user to select from multiple options for each feature or element that may be added to the mask blank. For example, there may be multiple storage bins each holding a different nose clip, multiple storage bins each holding a different exhalation valve, multiple storage bins each holding a different decorative cover (which may optionally be attached to the mask exterior), multiple storage bins each holding a different seal section material (e.g., a different type, size, or shape of material), and/or multiple storage bins each holding a different strap/head attachment system. Thus, for example, in some embodiments, the processor may select a sealing material and send attachment instructions to the mask modification module (including a location for attachment, e.g., 5mm from one or more of the edges of the mask). Additionally, in some embodiments, the user may be able to select the position of the exhalation valve, wherein the cutting element 926c then cuts an aperture (of the appropriate size and/or shape for the selected valve) at the selected position, and the attachment device 927c attaches the selected valve over the cut aperture. Of course, one or all of these stations and/or features/elements may be optional, and different mask modification modules may make any or all of these features optional (e.g., any of these features may be included or excluded). Thus, for example, the intermediate mask-modifying module may already have a blank with a pre-attached sealing section, nose clip, and/or valve, and a strap and/or decorative cover (and/or fragrance or chemical spray) may be added (e.g., via an attachment device) to the selected mask blank after cutting. The exact amount of mask customization available from any particular vending machine may depend on business or marketing decisions.

Methods for semi-custom mask formation and dispensing (e.g., at the point of purchase and at the time of purchase) in real-time (e.g., substantially immediately after placing an order and/or instructing mask formation/customization, and/or substantially immediately prior to dispensing masks) on-site (e.g., in situ) have been discussed above with respect to particular vending machine/kiosk embodiments to some extent. Alternative method embodiments for forming (e.g., in real-time and/or in situ) a semi-custom respiratory mask may include one or more of the following steps: obtaining facial image data (which may typically be 3D image data) of a user's face, such as front and side views taken by a camera or other image capture device; extracting facial details and/or measurements from facial image data; optionally obtaining preference information for the user (which may include preferred mask types and/or characteristics and/or filtering requirements and/or aroma preferences, e.g., obtained via an input device); selecting a mask blank from a plurality of different available mask blanks (which may also include providing a plurality of different mask blanks in some embodiments) based on facial image data and/or preferences (e.g., automatically based on instructions from a processor based on image data and/or preferences); modifying/customizing the selected mask blank based on the facial image data (e.g., automatically based on image data and/or preference-based instructions from the processor); and/or assigning the completed semi-custom mask to the user (e.g., automatically in real-time). Typically, such a method may be performed automatically, e.g., using a vending machine or kiosk at and/or close to the point of use for a semi-custom mask and/or in real-time (e.g., substantially immediately after the user places/purchases the semi-custom mask, which may, for example, mean that the kiosk immediately begins the process of semi-custom mask formation, such that the delay between placing/paying for the mask and dispensing the mask to the user may only be the amount of time that occurs as the semi-custom mask formation process proceeds). Typically, the actual physical mask formation of such a process may occur in-situ (e.g., at the point of purchase and/or close to the point of use) within a kiosk (e.g., within a housing for the kiosk/vending machine). Additionally, the mask modification module and the image capture device will typically be located within the same housing (e.g., within a kiosk housing and/or at the same location). Typically, the automatic processing may occur with the processor retrieving any user preferences and/or payments and then automatically controlling the image capture device, with the processor then retrieving facial image data from the image capture device, processing the data to form mask blank selection instructions and/or mask customization instructions, and then transmitting those instructions to a mask modification module within the vending machine for automatic formation and dispensing of semi-customized masks. Thus, the mask modification module will typically operate its steps in an automated fashion, automatically implementing instructions from the processor (e.g., selecting and customizing a mask blank).

In some method embodiments, mask modification/customization may include one or more of the following: cutting the selected mask blank according to instructions from the processor; heat molding the mask blank according to instructions from the processor; attaching straps to the selected mask blank according to instructions from the processor (which may in some embodiments include selecting straps from a plurality of different available straps for attachment of the mask to the user's face/head and/or attaching straps in a desired location and/or in a desired manner (e.g., forming an ear band or headband that may be customized in length)); attaching a nose clip to the selected mask blank according to instructions from the processor (which may include selecting a nose clip from a plurality of different available nose clips in some embodiments); cutting an aperture and/or attaching an exhalation valve to a selected mask blank according to instructions from the processor (which may include selecting a valve from a plurality of different available valves in some embodiments); and/or attaching and/or cutting sealing material to/from a selected mask blank (which may include selecting sealing material from a plurality of different available sealing materials in some embodiments). Some method embodiments may also include automatically spraying, for example, a chemical or fragrance onto the mask according to instructions from the processor, for example, based on user preferences. Useful mask blanks may include one or more flat-folded mask blanks and/or one or more molded cup-shaped mask blanks. And in some embodiments, one or more available mask blanks (e.g., in a frame) may include one or more of the following features/elements pre-attached to the mask blank filter material: exhalation valves, strips, sealing materials/sections, nose clips, and/or decorative covers. In embodiments in which one or more features/elements are pre-attached, the mask modification/customization instructions typically ensure that any cutting or other removal of the filter or mask blank material will not result in removal of the pre-attached feature (s)/element(s). The skilled artisan will appreciate that these disclosed method embodiments may be used with (and in relation to) any of the disclosed kiosk/vending machine devices described herein for forming any of the described mask embodiments described herein. In other words, such exemplary methods/processes may be performed using one or more of the apparatus embodiments described herein (e.g., the figure embodiments above and/or the additional embodiments below, where particular method steps relate to those apparatus elements/components employed herein).

FIG. 10 depicts a flow chart depicting an exemplary method of deriving a facial metric from image data. Fig. 10 and depicts an exemplary method 1000 of obtaining a facial metric from the perspective of processor 930 of the block diagram depicted in fig. 9. Method 1000 begins with processor 930 receiving facial image data, 1005. Processor 930 then initializes a counter, i, 1010. Processor 930 then performs operations to locate the ith feature in the image data, 1015. For example, processor 930 may determine the location of the nose and/or mouth (e.g., using facial recognition techniques). Processor 930 then determines one or more measurements corresponding to the located feature, 1020. Processor 930 then increments the counter, i, 1025. Processor 930 compares the incremented counter, i, with a predetermined maximum count, i_maxComparison is performed, 1030. If the counter, i, is less than the maximum count, i_maxThen processor 930 returns to step 1005 and locates a new ith feature in the image. However, if the count, i, is greater than the maximum count, i_maxThen the processor 930 stores the measurement obtained at step 1020 to a memory location 1035.

Fig. 11 depicts a flow chart describing an exemplary method of selecting a mask for use for customization. Fig. 11 and depicts exemplary method 1 of selecting a mask for use for customization from the perspective of processor 930 of the block diagram depicted in fig. 9100. The method begins with processor 930 retrieving 1105 measurement data from memory. For example, processor 930 may retrieve the measurement data stored in memory at step 1035 of the method depicted in fig. 10. Processor 930 then initializes a counter, m, 1110. The processor 930 then retrieves mask customizable feature data corresponding to the mask to be customized 1115. Processor 930 then calculates the required modifications to perform based on the received measurement data and retrieved mask customizable feature data, 1120. Processor 930 then increments the counter, m, 1125. Processor 930 then compares the counter to a predetermined maximum count, m_maxFor comparison, 1130. If the counter, m, is not greater than the maximum count m_maxThen the processor 930 returns to step 1115 and retrieves mask customizable feature data corresponding to the new count m. However, if the counter, m, is greater than the maximum count, m_maxThen processor 930 classifies the calculated modification data from those requiring the least modification to those requiring the most modification 1135. Processor 930 then selects the mask that requires the least modification, 1140. Processor 930 then retrieves mask data corresponding to the selected mask, 1145. The processor 930 then sends modification instructions to the mask selection engine corresponding to the mask modifications required for the selected mask 1150.

FIG. 12 depicts a flow chart describing an exemplary method for customizing a mask for a user. Fig. 12 and from the perspective of the processor 930 of the block diagram depicted in fig. 9 depicts an exemplary method 1200 of customizing a mask for a user. The method begins with processor 930 initializing a counter, n, 1205. Processor 930 then retrieves the mask's feature data corresponding to the index of counter, n, 1210. Processor 930 then retrieves measurement data corresponding to the particular measurement of the facial feature corresponding to index n 1215. Processor 930 then compares the facial measurements to mask features corresponding to index n, 1225. If the measurement data is greater than the mask characteristic, then processor 930 determines if the mask can be modified to accommodate the negative difference, 1235. Similarly, if the measurement data is less than the mask data, processor 930 determines whether the mask is acceptableTo be modified to accommodate the positive difference value, 1230. In steps 1230 and 1235, if the mask can be modified, the processor 930 sends modification instructions to the modification engine, 1240, 1245. If the mask cannot be modified or after modification instructions have been sent to the modification engine, processor 930 increments a counter, n, 1250. Processor 930 then compares the counter, n, with the maximum count, n_maxFor comparison 1255. If the counter, n, is less than or equal to the maximum count, n_maxThen processor 930 returns to step 1210 and retrieves the next mask feature data corresponding to the incremented index n. However, if the counter, n, is greater than the maximum count, n_maxThen the method ends.

In some embodiments, fit data for a sealing interface between a mask and a wearer's face may be used to determine the quality of the fit. For example, an exemplary Method of determining mating quality based on a sealing interface is described with reference to at least [ page 3, line 28 to page 5, line 29 ] of U.S. patent application 13/839,056 entitled "System and Method for selecting a responder" filed 2013, month 3, 15 and FIG. 1, the entire disclosure of which is incorporated herein by reference.

In some embodiments, the internal volume between the mask and the wearer may be calculated to determine the fit quality. For example, an exemplary Method of determining the quality of fit based on internal volume is described with reference to at least [ page 16, line 27 to page 17, line 8 ] and fig. 7 in U.S. patent application 13/839,186 entitled "System and Method for Selecting an alignment marker" filed 2013, month 3, 15, the entire disclosure of which is incorporated herein by reference.

In some embodiments, a fit quality metric for a mask may be determined based at least in part on a series of points by assigning semantic information to a mask model. An exemplary method for determining the quality of fit based on such a method is described, for example, with reference to at least [ page 1, line 22 to page 2, line 33 ] of U.S. patent application 61/814,897 entitled "System and method for Selection PPE" filed 2013, 4/23 and fig. 1, the entire disclosure of which is incorporated herein by reference.

In some embodiments, a graphical user interface may be used to display the fit quality metric to the user. Exemplary graphic display images are described, for example, with reference to at least fig. 1-5 of U.S. patent application 61/814,905 entitled "System and Method for Evaluating PPE Fit" filed 2013, 4-23, the entire disclosure of which is incorporated herein by reference. In some embodiments, for example, the vending machine (e.g., via a graphical user interface) may provide one or more mask recommendations (e.g., recommendations of mask blanks and one or more add-ons) to the user based on the quality fit metrics and/or the input user preferences. And in some embodiments, the vending machine (e.g., via a graphical user interface) may also make recommendations based on local current atmospheric conditions (e.g., perhaps sensing atmospheric quality and/or receiving reports of atmospheric quality from remote sensors, and then determining the best masks (or ranking mask effectiveness) based on those atmospheric conditions).

In some embodiments, a graphical user interface may be used to provide a user interface between the mask fitting system and the user. Exemplary methods of implementing such graphical user interfaces are described, for example, with reference to at least [0021- > 0022] and fig. 1-2 of U.S. patent application 61/861,294 entitled "Virtual Mask fixing System" filed on 8/1 of 2013, the entire disclosure of which is incorporated herein by reference.

In some embodiments, the method of virtually fitting a mask model to a wearer's face may be performed by: a virtual fit of the chin region is first performed and then the mask model is virtually rotated towards or away from the virtual face to fit the nose-bridge region. An exemplary method of performing such Virtual mating is described, for example, with reference to at least [ 0030-.

Having described various product/device/system and method/process embodiments (particularly those shown in the various figures) above, various additional embodiments may include, but are not limited to, the following:

in a first embodiment, an (on-site) (semi-custom (e.g., custom/personalized)) respiratory (e.g., dust-proof) mask dispensing apparatus (e.g., a vending machine, photo kiosk, or kiosk for customizing a respiratory mask for a particular user) includes: an image capture device, such as a camera or 3-D face scanner (e.g., operable to capture 3-D facial image data from a user (which may require multiple uses of the camera when the user is oriented/positioned differently (e.g., frontal and side views)); a mask modification module (that houses multiple (different) mask blanks and) operable to convert the mask blanks into semi-custom masks (e.g., personalized/customized for a user); and a processor (or mask optimization control module) operable to use image data from the image capture device to generate instructions to the mask modification module (e.g., send mask blank selection instructions such that the mask modification module selects an appropriate mask blank for modification and send mask customization instructions (e.g., operations) such that the mask modification module appropriately customizes/modifies the selected mask blank) in relation to creating a semi-custom mask from available mask blanks. In a second embodiment, the device of embodiment 1 further comprises a (vending machine) housing enclosing at least the image capture device and the mask modification module, wherein the housing is sufficiently sized and configured to allow the device to be placed in motion in various (vending machine) locations (e.g., the vending machine can be transported as a complete unit between locations and easily/conveniently fitted (set-up) -e.g., simply by plugging into a power outlet) (wherein the housing can be located at a point-of-purchase location and provide the user with a semi-custom mask in real-time (e.g., wherein (e.g., due to immediate formation of the mask) there is only a short delay (about 25 seconds, less than 2 minutes, less than 1 minute, less than 30 seconds, or 25 seconds or less)) between, e.g., the customer placing an order for the mask and receiving the mask). In a third embodiment, the device of embodiment 2, wherein the processor is also located within the housing (although in other embodiments the processor may be remotely located but in communication with the image capture device and the mask modification module within the housing at the point of purchase location (e.g., via wireless transmission to a wireless transmitter and/or receiver located within the housing)). In a fourth embodiment, the device of embodiments 1-3 further comprises an input device operable to receive information (e.g., personal preference information and/or payment information) from a user and transmit the user information to the processor (where such user information may be used to assist in selecting mask blanks or mask customizations (e.g., the personal preference information may be used in generating selection instructions and/or customization instructions)). In a fifth embodiment, the device of embodiments 1-4 further comprises an output device operable to allow the processor to communicate with the user (e.g., communicate with the processor to provide instructions to the user, for example, regarding positioning for image capture and/or displaying mask preference selections). In a sixth embodiment, the apparatus of embodiments 1-5, wherein the mask modification module further comprises: one or more frames, wherein each of the frames holds a plurality of identical mask blanks, and each of the mask frames holds a different type of mask blank (e.g., a different mask blank size, shape, and/or class (e.g., flat folded or molded cup-shaped) and/or pre-installed feature(s) (e.g., nose clip, strap mechanism, exhalation valve, etc.) and/or filtering level) than the other frames of the mask blank, wherein the one or more frames are operable to hold and dispense mask blanks for customization (e.g., upon receiving (mask blank selection) instructions from a processor or mask optimization control module); and a mask modifying element (e.g., operable to modify (e.g., size and/or shape of) the selected mask blank in accordance with mask customization instructions from the processor). In a seventh embodiment, the apparatus of embodiment 6, wherein the mask-modifying element is a cutting element (such as a blade or laser cutter, which may optionally be located on a robotic arm or gantry operable to move/reposition the cutter) and/or heat a die (operable for stamping the mask blank). In an eighth embodiment, the apparatus of embodiments 6-7, wherein the mask modification module further comprises a dispensing mechanism (e.g., a hopper gravity-fed from a conveyor belt, etc.) operable to dispense the finished/finished semi-custom mask to a user (e.g., upon completion of operation of the mask modifying element). In a ninth embodiment, the apparatus of embodiments 6-8, wherein the mask modification module further comprises a delivery mechanism (e.g., conveyor belt(s) or mechanical arm (s)) operable to move the selected mask blank at least from the chassis to the mask-modifying element, and/or then to the dispensing mechanism (and wherein in some embodiments the dispensing mechanism is part of the delivery mechanism). In a tenth embodiment, the apparatus of embodiments 6-9, wherein the mask modification module has a restraining mechanism (e.g., having a mechanical restraint or vacuum suction) operable to securely hold the selected mask blank in place/location during mask modification (e.g., during cutting by the cutting element) (and in some embodiments, the restraining mechanism may be part of a transport mechanism/system-such as a restraining clip on a conveyor belt). In an eleventh embodiment, the apparatus of embodiments 6-10, wherein the mask modification module further comprises an attachment device/mechanism operable to (permanently) attach one or more (optional) features or elements (e.g., straps, nose clips, exhalation valves, decorative covers, and/or sealing section materials/foams) to the mask blank (according to mask customization instructions). In a twelfth embodiment, the apparatus of embodiment 11, wherein the attachment apparatus further comprises one or more storage elements/boxes/racks that hold optional feature/element assemblies that can be used for selection (according to selection instructions from the processor) and attachment (according to mask customization instructions from the processor) of mask blanks. In a thirteenth embodiment, the apparatus of embodiments 11-12, wherein the attachment apparatus further comprises an adhesive applicator or a welding apparatus (e.g., an ultrasonic welding machine) (the adhesive applicator or welding apparatus may optionally be mounted on a robotic arm or gantry operable to position or move the attachment apparatus). In a fourteenth embodiment, the device of embodiments 11-13, wherein the attachment device further comprises a strap reel attached to the attachment device, and the strap reel is operable to automatically dispense the strap for attachment to the mask blank (e.g., according to mask customization instructions from the processor). In a fifteenth embodiment, the apparatus of embodiments 11-14 wherein the mask customization instructions include instructions regarding selecting optional features/elements for inclusion on the semi-customized mask (and optionally may also include position/location instructions for one or more selected optional features/elements). In a sixteenth embodiment, the apparatus of embodiments 1-15, wherein the apparatus is operable to provide a semi-custom mask (e.g., a mask made from a mask blank at the point of purchase) to the user at the point of purchase in real time (e.g., based on facial image data and/or personal preference information of the user) (and/or wherein the apparatus is operable to be moved to another location as a unitary/integrated unit and/or the housing is sized to have a footprint that is less than or equal to a typical vending machine or kiosk size, such as less than about 61 inches by 40 inches deep, less than about 45 inches by 40 inches deep, about 1.1 meters by 0.9 meters deep, about 57 inches by 29 inches deep, about 61 inches by 39 inches deep, or about 39 inches by 33 inches, so that the apparatus can be used at a typical vending machine location). In a seventeenth embodiment, the apparatus of embodiments 1-16, wherein the mask blank selection instructions generated by the processor use the measured facial dimensions/image data to select a mask blank according to five basic demographic facial shapes (e.g., long-narrow, small, medium, large, and short-wide). In an eighteenth embodiment, the apparatus of embodiments 1-17, wherein the mask customization instructions generated by the processor use a surface flattening mechanism to modify the measured facial dimensions/image data to then create cutting instructions (e.g., for a flat-fold type mask blank). In a nineteenth embodiment, the apparatus of embodiments 1-18, wherein the processor/mask optimization control module comprises one or more of: a mask blank selection module, a mask blank customization calculator/module, a mask decoration module, and/or a memory store for facial image data storage, critical dimension data storage, and/or a mask database). In a twentieth embodiment, the device of embodiments 1-19, wherein the instructions from the processor comprise signals (e.g., via wired or wireless transmission). In a twenty-first embodiment, the apparatus of embodiments 1-20, wherein the instruction from the processor to the mask modification module (e.g., the mask blank selection instruction and/or the mask customization instruction) is based on one or more of the following measured facial image data: cheekbone width, mandibular angle width, nose-protrusion distance, nose width, lip length, subnasal point nose bridge point length, submental point-subnasal point length, facial depth, tragus point-subnasal point arc, tragus point-submental point arc, and submental point-nose bridge point length (e.g., when the processor extracts these measurements from facial image data sent from the image capture device). In a twenty-second embodiment, the apparatus of embodiments 12-21, wherein the storage case comprises a plurality of nose clip bins, wherein each of the plurality of bins has a differently sized and/or shaped and/or material nose clip than the other nose clip bins, and wherein each particular nose clip bin has a plurality of identical nose clips (e.g., bin a has only a type a nose clips and the other bins do not have a type a nose clips; bin B has only B type nose clips and the other bins do not have B type nose clips, etc.). In a twenty-third embodiment, the apparatus of embodiments 12-22, wherein the storage tank comprises a plurality of exhalation valve boxes, wherein each of the plurality of boxes has a different type of exhalation valve than the other exhalation valve boxes, and wherein each particular box has a plurality of identical exhalation valves (e.g., box a has only a type a valves and the other boxes do not have type a valves; box B has only B valves and the other boxes do not have B valves, etc.). In a twenty-fourth embodiment, the apparatus of embodiments 12-23, wherein the storage bin comprises a plurality of decorative cover bins, wherein each of the plurality of bins has a different type of decorative cover than the other decorative cover bins, and wherein each particular bin has a plurality of identical decorative covers (e.g., bin a has only a type a decorative covers and the other bins do not have a type a decorative covers; bin B has only B type decorative covers and the other bins do not have B type decorative covers, etc.). In a twenty-fifth embodiment, the apparatus of embodiments 12-24, wherein the storage bin comprises a plurality of strip bins (which may be rolls, etc.), wherein each of the plurality of bins has a different type of strip than the other strip bins, and wherein each particular bin has a plurality of identical strips (e.g., bin a has only a type strips and the other bins do not have a type strips; bin B has only B type strips and the other bins do not have B type strips, etc.). In a twenty-sixth embodiment, the apparatus of embodiments 12-25, wherein the storage bin comprises a plurality of bins of sealing material, wherein each of the plurality of bins has a different type of sealing material (including material, size, and/or shape) than the other bins of sealing material, and wherein each particular bin has a plurality of the same sealing material (e.g., bin a has only a type of sealing material and the other bins do not have a type of sealing material; bin B has only B type of sealing material and the other bins do not have B type of sealing material, etc.). In a twenty-seventh embodiment, the apparatus of embodiments 12-25, wherein the storage box is operable to automatically assign appropriate features/elements from the one or more storage boxes in response to instructions from the processor (e.g., mask customization instructions) (e.g., wherein the assigned features/elements are then positioned relative to the mask blank and secured to the mask blank using the attachment mechanism). In a twenty-eighth embodiment, the apparatus of embodiments 1-27, wherein the mask customization instructions comprise instructions to cut/form an aperture in the mask (perhaps at a selected location, e.g., based on user preferences) for interacting with the selected/dispensed exhalation valve (e.g., where an attachment mechanism attaches the exhalation valve in a sealed manner over the formed aperture). In a twenty-ninth embodiment, the apparatus of embodiments 1-28, wherein the semi-custom mask is formed in-situ at a location of the vending machine (e.g., a housing or point of purchase or point of need) and/or in-situ in real-time (e.g., proximate to a time of order placement and/or purchase and/or distribution to the user/customer). In a thirtieth embodiment, the device of embodiments 1-29, wherein the device further comprises a sensor (typically located on the housing) operable to detect an air condition (e.g., a pollution level and/or a pollutant) and recommend a mask characteristic based on the sensed data (e.g., wherein the processor communicates with the user via the output device). In a thirty-first embodiment, the apparatus of embodiments 6-30, wherein the frame of mask blanks may comprise mask blanks having different filtering capabilities (so that, for example, a user may select a desired/required level of respiratory protection). In a thirty-second embodiment, the apparatus of embodiments 6-31, wherein the frame has a mask blank with one or more features/elements/accessories pre-attached to the filter material. In a thirty-third embodiment, the apparatus of embodiments 6-32, wherein the frame has at least 5 (e.g., one mask blank for each of five standard demographic face types), at least 10, 10-20, 10-50, 15-20, or 20-50 different available mask blanks (e.g., different sizes, shapes, categories (e.g., flat folded or molded cups), filtering capabilities, and pre-attached attachments/features/elements of the mask blanks) (and/or wherein each frame typically has at least 10, 10-20, 10-50, 15-20, or 20-50 identical mask blanks). In a thirty-fourth embodiment, the apparatus of embodiments 1-33, wherein the apparatus further comprises a transmitter operable to signal (e.g., an electronic message sent to a central station for maintenance of a plurality of such vending machines) when the apparatus requires restocking of mask blanks and/or features/elements/accessories, and/or requires maintenance or repair. In a thirty-fifth embodiment, the apparatus of embodiments 13-34 further comprises a mask cooling mechanism (e.g., a fan) operable to cool the finished semi-custom mask prior to distribution to the user (e.g., to ensure that the adhesive is not too hot and potentially burning the user, and/or to ensure that the adhesive has sufficiently and/or more quickly solidified the attachment). The skilled person will understand that several disclosed embodiments may be similar, so that the description attributed to a particular embodiment may also be applied to other similar embodiments.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are merely representative and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments resulting from combining, integrating, and/or omitting features or steps of the embodiment(s) are also within the scope of the present disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is instead defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as a further disclosure, and the claims are examples of the invention(s). Still further, any advantages and features described above may relate to particular embodiments, but the application of such issued claims should not be limited to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Additionally, the section headings used herein are provided to conform to the suggestions according to 37c.f.r.1.77 or to otherwise provide organizational cues. These headings should not limit or characterize the invention(s) made in any claims that may issue from this disclosure. In particular and by way of example, although a title may refer to a "realm," the claims should not be limited by the language chosen under this title to describe a so-called realm. Further, the description of technology in the "background" is not to be construed as an admission that certain technology is prior art to any invention(s) in the present disclosure. The summary of the invention is also not to be considered a limiting characterization of the invention(s) set forth in the issued claims. Furthermore, any reference in this disclosure to "invention" in the singular should not be used to claim that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s) protected thereby and their equivalents. In all instances, the scope of the claims should be considered in their own right in light of the disclosure, but should not be constrained by the headings set forth herein.

Use of broader terms such as including, containing, and having should be understood to provide support for narrower terms (such as consisting of …, consisting essentially of …, and consisting essentially of …). The use of the terms "optionally," "may," "possible," and "having" and the like in reference to any element of an embodiment means that the element is not required, or alternatively, that the element is required, both alternatives being within the scope of the embodiment(s). Additionally, references to examples are provided for illustrative purposes only and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.

In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Many implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different order, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented by other components. Accordingly, other implementations are contemplated. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims (11)

1. An apparatus, comprising:

an image capture device operable to capture facial image data from a user;

a mask modification module operable to convert a mask blank into a semi-custom mask; and

a processor operable to use image data from the image capture device to generate instructions for the mask modification module in relation to creating a semi-custom mask from available mask blanks;

wherein the mask modification module further comprises:

one or more racks, wherein each of the racks holds a plurality of identical mask blanks and each of the mask racks holds a different type of mask blank than the other mask blank racks, wherein the one or more racks are operable to hold mask blanks and automatically dispense mask blanks for customization upon receipt of instructions from the processor; and

a mask modifying element operable to modify the selected mask blank according to instructions from the processor; and is

Wherein the mask modification module automatically converts mask blanks according to instructions from the processor.

2. The device of claim 1, further comprising a kiosk housing enclosing at least the image capture device and mask modification module, wherein the housing is sufficiently sized and configured to allow for mobile placement of the device at various locations.

3. The apparatus of claim 1, wherein the mask-modifying element comprises a cutting element and/or a heated mold.

4. The apparatus of claim 1, wherein the mask modification module further comprises an attachment mechanism operable to automatically attach one or more features to the selected mask blank according to instructions from the processor.

5. The apparatus of claim 4, wherein the attachment mechanism further comprises one or more memory elements that hold feature components that are available for selection and attachment to a selected mask blank;

wherein the storage element comprises a plurality of nose clip storage elements, wherein each of the plurality of nose clip storage elements has a nose clip that is sized and/or shaped and/or material differently than the other nose clip storage elements, and wherein each particular nose clip storage element has a plurality of identical nose clips; and wherein the storage element further comprises a plurality of exhalation valve storage elements, wherein each of the plurality of exhalation valve storage elements has a different type of exhalation valve than the other exhalation valve storage elements, and wherein each particular exhalation valve storage element has a plurality of identical exhalation valves.

6. The apparatus of claim 5, wherein the instructions from the processor include instructions regarding selecting features for inclusion on a semi-custom mask.

7. The apparatus of claim 1, wherein the instructions generated by the processor use the facial image data to select mask blanks according to five basic demographic facial shapes.

8. The device of claim 1, wherein the instructions from the processor to the mask modification module are based on one or more of the following facial image data: cheekbone width, mandible angle width, nose-protrusion distance, nose width, lip length, subnasal point nose bridge point length, subchin-subnasal point length, facial depth, tragus point-subnasal point arc, tragus point-subchin arc, and subchin-nose bridge point length.

9. The device of claim 8, wherein the processor extracts one or more of the following from facial image data sent from the image capture device: cheekbone width, mandible angle width, nose-protrusion distance, nose width, lip length, subnasal point nose bridge point length, subchin-subnasal point length, facial depth, tragus point-subnasal point arc, tragus point-subchin arc, and subchin-nose bridge point length.

10. The apparatus of claim 1, wherein the mask blank frame comprises mask blanks having different filtering capabilities.

11. The apparatus of claim 1, wherein the frame comprises a mask blank having one or more features pre-attached to mask blank filter material.

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