System and Method for Forming a Custom Medical Mask Using an Orientation Device

Abstract

According to one embodiment, forming a custom medical mask includes, while an oral appliance is positioned in a user's mouth to receive the user's teeth and is coupled to an orientation device, applying an impression material over the device and the user's face, such that the impression material conforms to the device and to the user's unique facial features. The impression material may be removed together with the device and a cast may be created using the impression material together with the device as a mold, such that the cast conforms to the impression material and the device. A deformable material may be applied to the cast to form a custom medical mask for the user, such that the deformable material conforms to the cast. The custom medical mask is custom-fitted to the user's unique facial features and custom-oriented to the user's teeth.

1 . A method of forming a custom medical mask for a particular user, comprising:
 while an oral appliance is positioned in the particular user's mouth to receive the particular user's teeth and is coupled to an orientation device using a post of the oral appliance, applying an impression material over the orientation device and the particular user's face including at least the particular user's mouth and a portion of the particular user's nose surrounding the particular user's nostrils, such that the impression material conforms to the orientation device and to the particular user's unique facial features;   removing the impression material from the particular user's face together with the orientation device, creating a cast of the particular user's face using the impression material together with the orientation device as a mold, such that the cast conforms to the impression material and the orientation device; and   applying a deformable material to the cast of the particular user's face to form a custom medical mask for the particular user, such that the deformable material conforms to the cast;   wherein the custom medical mask is custom-fitted to the particular user's unique facial features and custom-oriented to the particular user's teeth.   
     
     
         2 . The method of  claim 1 , further comprising inserting into the orientation device a second post corresponding to the oral appliance post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the second post within the orientation device. 
     
     
         3 . The method of  claim 2 , further comprising coupling a locking mechanism to the second post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism. 
     
     
         4 . The method of  claim 1 , further comprising removing the impression material from the particular user's face together with the orientation device and the post of the oral appliance, such that when the deformable material is applied to the cast the deformable material further conforms to the post of the oral appliance. 
     
     
         5 . The method of  claim 4 , further comprising coupling a locking mechanism to the post of the oral appliance, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism. 
     
     
         6 . The method of  claim 1 , wherein the orientation device comprises at least one breathing passage configured to allow the particular user to breathe when the particular user's mouth is covered with the impression material. 
     
     
         7 . The method of  claim 1 , wherein the orientation device comprises:
 an elongated tubular member configured to receive the oral appliance post; and   a restraining structure configured to limit movement of the orientation device relative to the oral appliance.   
     
     
         8 . The method of  claim 7 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth. 
     
     
         9 . The method of  claim 1 , wherein the deformable material comprises a thermoplastic polymer and is heated to transition to a deformable state prior to applying the deformable material to the cast. 
     
     
         10 . The method of  claim 9 , wherein the thermoplastic polymer comprises a polycaprolactone polymer. 
     
     
         11 . The method of  claim 1 , further comprising:
 creating openings in the custom medical mask corresponding to the particular user's nostrils; and   coupling a fitting for a clinical gas delivery system to the custom medical mask for supplying a gas to the particular user's nostrils through the openings in the custom medical mask.   
     
     
         12 . A method for use in forming a custom medical mask for a particular user, comprising:
 while an oral appliance is positioned in the particular user's mouth to receive the particular user's teeth and is coupled to an orientation device using a post of the oral appliance, applying an impression material over the orientation device and the particular user's face including at least the particular user's mouth and a portion of the particular user's nose surrounding the particular user's nostrils, such that the impression material conforms to the orientation device and to the particular user's unique facial features;   removing the impression material from the particular user's face together with the orientation device; and   creating a cast of the particular user's face using the impression material together with the orientation device as a mold, such that the cast conforms to the impression material and the orientation device.   
     
     
         13 . The method of  claim 12 , wherein the orientation device comprises at least one breathing passage configured to allow the particular user to breathe when the particular user's mouth is covered with the impression material. 
     
     
         14 . The method of  claim 12 , wherein the orientation device comprises:
 an elongated tubular member configured to receive the oral appliance post; and   a restraining structure configured to limit movement of the orientation device relative to the oral appliance.   
     
     
         15 . The method of  claim 14 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth. 
     
     
         16 . A method of forming a custom medical mask for a particular user, comprising:
 accessing a cast of the particular user's face that conforms to an orientation device and has been formed using an impression material together with the orientation device as a mold, the impression material having been:
 applied over the orientation device and the particular user's face including at least the particular user's mouth and a portion of the particular user's nose surrounding the particular user's nostrils, while an oral appliance was positioned in the particular user's mouth to receive the particular user's teeth and was coupled to the orientation device using a post of the oral appliance, 
 removed from the particular user's face together with the orientation device; and 
   applying a deformable material to the cast of the particular user's face to form a custom medical mask for the particular user, such that the deformable material conforms to the cast;   wherein the custom medical mask is custom-fitted to the particular user's unique facial features and custom-oriented to the particular user's teeth.   
     
     
         17 . The method of  claim 16 , further comprising inserting into the orientation device a second post corresponding to the oral appliance post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the second post within the orientation device. 
     
     
         18 . The method of  claim 17 , further comprising coupling a locking mechanism to the second post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism. 
     
     
         19 . The method of  claim 16 , wherein when the deformable material is applied to the cast, the deformable material further conforms to the post of the oral appliance, the post of the oral appliance having been removed together with the impression material and the orientation device from the particular user's face. 
     
     
         20 . The method of  claim 19 , further comprising coupling a locking mechanism to the post of the oral appliance, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism 
     
     
         21 . The method of  claim 16 , wherein the orientation device comprises at least one breathing passage configured to allow the particular user to breathe when the particular user's mouth is covered with the impression material. 
     
     
         22 . The method of  claim 16 , wherein the orientation device comprises:
 an elongated tubular member configured to receive the oral appliance post; and   a restraining structure configured to limit movement of the orientation device relative to the oral appliance.   
     
     
         23 . The method of  claim 22 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth. 
     
     
         24 . The method of  claim 16 , wherein the deformable material comprises a thermoplastic polymer and is heated to transition to a deformable state prior to applying the deformable material to the cast of the particular user's face. 
     
     
         25 . The method of  claim 24 , wherein the thermoplastic polymer comprises a polycaprolactone polymer. 
     
     
         26 . A system for use in forming a custom medical mask for a particular user, comprising:
 an oral appliance comprising:
 an upper arch configured to be positioned within a particular user's mouth to receive the particular user's upper teeth; and 
 a post coupled to the upper arch and configured to protrude from the particular user's mouth when the upper arch is positioned within the particular user's mouth; 
   an orientation device comprising:
 an elongated tubular member configured to receive the oral appliance post to couple the orientation device to the oral appliance; and 
 a restraining structure configured to limit the movement of the orientation device relative to the oral appliance; and 
   an impression material conformed to the orientation device and the particular user's unique facial features and custom-oriented to the particular user's teeth via the orientation device and the oral appliance.   
     
     
         27 . The system of  claim 26 , wherein the orientation device further comprises at least one breathing passage configured to allow the particular user to breathe when the particular user's mouth is covered with the impression material. 
     
     
         28 . The system of  claim 26 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth. 
     
     
         29 . The system of  claim 26 , further comprising a locking mechanism configured to receive and secure the post of the oral appliance to couple the custom medical mask to the oral appliance. 
     
     
         30 . The system of  claim 26 , wherein the particular user's unique facial features comprise the particular user's mouth and a portion of the particular user's nose surrounding the nostrils 
     
     
         31 . A custom medical mask, comprising:
 a deformable thermoplastic polymer conformed to a custom mold of particular user's unique facial features and custom-fitted to the particular user's unique facial features, the particular user's unique facial features including portions of the particular user's face surrounding the particular user's mouth and at least portions of the particular user's nose; and   a locking mechanism configured to receive and secure a post of an oral appliance to maintain a custom orientation between the oral appliance and the custom-fitted thermoplastic polymer.   
     
     
         32 . The custom medical mask of  claim 31 , further comprising a fitting configured to couple the custom medical mask to a clinical gas delivery system. 
     
     
         33 . The custom medical mask of  claim 31 , wherein the thermoplastic polymer comprises a polycaprolactone polymer.