WO2015195303A1 - Kiosk for customizing facial breathing masks - Google Patents

Abstract

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

Description

KIOSK FOR CUSTOMIZING FACIAL BREATHING MASKS CROSS-REFERENCE TO RELATED APPLICATIONS

[001] This application is a PCT application which claims priority benefit to co- pending U.S. Provisional Patent Application Serial No. 62/015,249, filed on June 20, 2014, and entitled“Customizing Facial Breathing Masks Based Upon Facial Image Data”, which is hereby incorporated by reference for all purposes as if reproduced in its entirety.

[002] This application also fully incorporates the disclosures of the following previously submitted applications by reference herein, to the extent that it is not inconsistent with or directly contradictory of the present disclosure:

13/839,056 System and Method for Selecting a March 15, 2013

Respirator 13/839,186 System and Method for Selecting a March 15, 2013

Respirator 61/814,897 System and Method for Selecting PPE April 23, 2013 61/814,905 System and Method for Evaluating PPE Fit April 23, 2013 61/861,294 Virtual Mask Fitting System August 1, 2013 61/917,171 Virtual Mask Alignment for Fit Analysis December 17, 2013 PCT/ Virtual Mask Alignment for Fit Analysis March 12, 2014 US2014/024098 TECHNICAL FIELD

[003] Various embodiments relate generally to customizing facial breathing masks based upon image data corresponding to a person’s face, for example with such customization possibly occurring in real-time and/or in situ. BACKGROUND

[004] Hazardous breathing environments may arise in certain job environments. For example, while constructing a new home, cutting gypsum board may generate fine dust. This fine dust can be dangerous if inhaled by a worker. When sawing lumber, sawdust may be a byproduct of the operation. When texturing ceilings, particles may be generated. And when painting walls and/or ceilings, paint droplets may be created and put into the atmosphere. Newly laid carpet may release fibers into the air. And, old buildings may have asbestos which can, if care is not taken, be put into the air.

[005] Breathing masks have been widely used in hazardous environments and/or potentially hazardous environments. Such mask have been used when particles are generated. Breathing masks also may be used if dangerous chemicals are in the atmosphere. Some air masks may have chemical agents to neutralize toxic gases. Some breathing masks can be coupled to a safe source of breathable air. Some breathing masks can be connected to portable tanks of breathable air.

[006] Many industrial operations may cause air pollution by creating contaminants and injecting them into the atmosphere. Burning of coal or other materials can generate particles in the atmosphere. Chemical companies may produce chemical vapors which may be released into the atmosphere. Additionally, some large urban centers have dangerous levels of air pollution at certain times and/or seasons. In such large urban centers, many people can be exposed to these polluted atmospheres. Thus, there may be a need for additional, non-industrial users to have ready access to breathing masks. In the past, breathing masks were typically sold as-is; but as more non-traditional (e.g. non-industrial) users begin using masks, there may be a need for provision of more customized breathing masks in non-industrial settings. SUMMARY

[007] Given the various segmentation of the customers (for example regarding age, gender, region, facial-type, personal and/or aesthetic preference, mask decoration needs, etc.), it may be useful to offer customized or semi-custom breathing masks. And in some settings (for example in crowded areas (such as a Metro station) or bad air quality areas), it may be useful to offer semi-custom breathing masks available in real-time and/or in situ (for example, via an automated kiosk or vending machine). Such a semi-custom breathing mask kiosk/vending machine might be able to provide customized masks through scanning the user’s face (e.g. to capture facial image data and/or key dimensions of a user’s face (for example through scanning or taking pictures)), for example allowing for automatic selection of an appropriate mask blank (typically from available mask blanks within the device on site) and/or automatic forming of the selected mask blank based on the individual user’s facial measurements. Premium kiosk devices might even be able to offer further customization options, for example regarding other features of as breathing mask. Thus, individualized/personalized/customized masks might be provided in real-time (e.g. immediately) at the needed location. This type of semi-custom mask provision may become particularly useful as masks become more commonplace, for example used by regular customers going about their normal, everyday lives in urban centers with air quality/pollution concerns, since real-time, in situ delivery of semi-custom masks may better address such non-industrial user needs (e.g. providing a better delivery system for non- industrial users).

[008] Apparatus (for example vending machines or kiosks) and associated method embodiments may relate to facial breathing masks having selectively removable material which, when removed, may alter one or more facial fitting dimensions to provide a custom fit to a wearer’s face. In an illustrative embodiment, the facial breathing mask may be customized based upon facial dimensions determined using image data corresponding to a wearer’s face. In some embodiments, a mask customization module may modify the shape and/or size of the facial breathing mask. A processor may select, from different mask blanks, an optimal mask blank corresponding to image data corresponding to the wearer’s face. The processor may determine the customization operation to perform on the selected mask blank based upon the image data and the selected mask blank. Some embodiments may provide mask customization based upon personal preferences. The apparatus or system embodiments may advantageously provide an optimally fitted mask and/or personally customized (for example, semi-customized) mask for the wearer. And beneficially, such customized masks may be provided in situ and/or in real-time in some embodiments.

[009] Various disclosed embodiments may achieve one or more advantages. In some embodiments, quality of exhalation may be improved by a selection of valve types, numbers, and/or direction, for example. For example, some embodiments may provide optimally fitting masks to a wearing population having many different facial geometries. In some embodiments, a system may recommend a style of breathing mask to a wearer based upon facial image data of the wearer. Such a system may provide custom fitting breathing masks quickly. Custom fitting masks may improve a wearer’s compliance with using a breathing mask. Various embodiments may improve the seal quality of a mask to a wearer’s face. Masks having a good facial seal may provide better protection against a hazardous exterior atmosphere. Various embodiments may help to express the personal identity and preferences of a wearer. A wearer may select a favorite style and/or color of a mask and/or scent for a mask, for example. Various embodiments may improve a wearer’s health by providing a selection of filter materials to protect against different environmental hazards (based on hazards at the site of purchase and/or user input regarding likely exposure, for example). Breathing masks that provide 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 of need for protection (e.g. where pollution is experienced or is expected to be experienced) and/or at the point-of-purchase, and typically may provide these semi-custom masks in real-time (e.g. immediately or with minimal delay during immediate customization). Thus, better mask/protection may be available where needed and when needed. Such a semi-custom real-time breathing mask provision may be particularly useful in non-industrial settings and/or for non-industrial users.

[0010] 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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 depicts an exemplary process of customizing a breathing mask for a user based upon optical image data.

[0012] FIGS. 2A-2C depict exemplary facial dimensions which may be used to customize a breathing mask.

[0013] FIGS. 3A-3C depict an exemplary flat-fold dust mask.

[0014] FIGS. 4A-4B depict an exemplary cup-shaped dust mask.

[0015] FIG. 5 depicts an exemplary breathing mask with an exemplary nose clip.

[0016] FIGS. 6A-6B depict exemplary breathing masks without nose clips.

[0017] FIGS. 7A-7C depict exemplary breathing masks with exemplary exhalation valves.

[0018] FIGS. 8A-8B depict exemplary breathing masks without exhalation valves.

[0019] FIG. 9A depicts a block diagram of an exemplary mask customization system. [0020] FIG. 9B depicts a block diagram of an exemplary mask modification (e.g. semi-customization) module.

[0021] FIG. 9C depicts a block diagram of an alternative exemplary mask modification (e.g. semi-customization) module.

[0022] FIG. 9D depicts a more detailed block diagram of an exemplary mask modification (e.g. semi-customization) module.

[0023] FIG. 10 depicts a flow chart that describes an exemplary method of obtaining facial metrics from image data.

[0024] FIG. 11 depicts a flow chart that describes an exemplary method of selecting a mask for use for customization.

[0025] FIG. 12 depicts a flow chart that describes an exemplary method for customizing a mask for a user.

[0026] Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0027] It should be understood at the outset that although illustrative implementations 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 not yet in existence. The 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.

[0028] The following brief definition of terms shall apply throughout the application:

[0029] The term "comprising" means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

[0030] The phrases "in one embodiment," "according to one embodiment," and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);

[0031] If the specification describes something as "exemplary" or an "example," it should be understood that refers to a non-exclusive example;

[0032] The terms "about" or“approximately" or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/-10%); and

[0033] If the specification states a component or feature "may," "can," "could," "should," "would," "preferably," "possibly," "typically," "optionally," "for example," "often," or "might" (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded (with both options supported for claiming purposes).

[0034] To aid understanding, this document is organized as follows. First, an exemplary customized-mask vending machine (or kiosk) is briefly introduced with reference to FIG. 1. Second, with reference to FIGS. 2A-2C, various facial dimensions which may be used in an exemplary mask customization system are described. Then, with reference to FIGS. 3A-8B, the discussion turns to exemplary embodiments of customizable breathing masks that illustrate various customizable features. Specifically, different types and styles of breathing masks will be described. Then block diagrams of exemplary mask customization systems are described with reference to FIGS. 9A-D. With reference to FIGS. 10-12, exemplary methods used in a mask customizing system are described. Finally, additional embodiments are described in language tracking the claims. [0035] FIG. 1 depicts an exemplary process of customizing a breathing mask for a user based upon optical (facial) image data. In the FIG. 1 depiction, a group of people 100 are waiting in a line or queue at a customizable-mask vending machine (or kiosk) 105. The customizable-mask vending machine 105 has a user input device 110, into which a buyer (or user) 115 is selecting a mask design. The customizable-mask vending machine 105 may have a camera (and/or a 3D scanner or other imager capture device) with which to obtain facial image data of the buyer 115. The customizable-mask vending machine 105 may use facial image data obtained via the camera (and/or a 3D scanner, etc.) to customize a mask blank corresponding to the user’s selected mask design. For example, the vending machine 105 may instruct a person/user for proper positioning (e.g. which direction to face and/or which distance from the camera), and then automatically take the user’s picture (or otherwise scan the user’s face) to capture the user’s facial image and provide facial image data for creation of the customized mask. The customizable-mask vending machine 105 may compare the facial image (and/or 3D model) data with mask geometry data to determine how to customize the mask blank to best fit the buyer’s face, for example. For example, the facial image date might allow the vending machine to select the best mask blank based on which of five basic facial types the individual facial image data most closely corresponds with. The group of people 100 may have various facial geometries and dimensions 120. The customizable-mask vending machine may determine a customization operation using one or more facial dimension metrics calculated from the facial image data and/or one or more corresponding metrics of the selected mask blank. The customizable-mask vending machine may then add material, remove material, and/or shape the mask blank corresponding to the determined customization operation 125. The customizable-mask vending machine 105 may finish the customization by decorating the customized mask blank in response to a user selected mask design (although in other embodiments, the decoration stage could be performed earlier in the process). The customizable-mask vending machine 105 may then receive payment and deliver the customized mask 130 to the buyer (although in other embodiments, the payment stage could occur earlier in the process, for example before mask customization occurs). The buyer may advantageously obtain a well-fitting mask 130 (e.g. a semi-customized mask more likely to offer effective protection) with a design pattern to his/her liking. Additionally, the user/buyer may be able to obtain the desired (semi-custom) mask in situ (for example, without having to visit a store) and/or in real-time.

[0036] FIGS. 2A-2C depict exemplary facial dimensions which may be used to customize a breathing mask. In FIG. 2A, a front elevation of a person’s face 200 includes dimensions that may be used in creating a well-fitting customized breathing mask. Annotated upon the person’s face is a Bizygomatic breadth dimension 205. This Bizygomatic breadth dimension 205 may be substantially the breadth of the user’s face from cheekbone to cheekbone. Also annotated upon the person’s face is a Bigonial breadth dimension 210. This Bigonial breadth 210 dimension may be substantially the breadth of the user’s face as measured form jaw-bone to jaw-bone. Also annotated in the nose-breadth 215 of the person’s nose 220. Finally, the lip length 225 of the person’s lips 230 are depicted. One or more of these facial dimensions may be measured and used by the vending machine.

[0037] In FIG. 2B, a side elevation of the person 200 includes further dimensions that may be used in creating a well-fitting customized breathing mask. Annotated on this figure is a Subnasal-Sellion Length 235. Also annotated is a Nose protrusion distance 240. A Menton-Sellion length 245 may be substantially the vertical distance from the bottom of the chin 250 to the nose-bridge 255 of the person’s face 200. Finally, the Menton-Subnasal length 255 may be substantially the vertical distance from the bottom of the chin 250 to the bottom of the nose 220 of the person’s face 200. [0038] In FIG. 2C, a side elevation of the person 200 includes further dimensions that may optionally be used in creating a well-fitting customized breathing mask. Annotated on this figure is a depth of face dimension 260. Also annotated is a Tragion-Subnasal Arc length 265 and a Tragion-Menton Arc length 270. Other critical facial dimensions may be used in determining a customization to a mask or mask blank. One or more facial dimensions may be used in creating a customize breathing mask. In some mask customizing systems, for example, a sealing surface may be made to conform to a user’s face. The sealing surface may circumscribe the user’s nose and/or mouth, for example. In some embodiments, material may be added to a mask blank to ensure an integrity mask/skin interface. In an exemplary embodiment, material may be subtracted from a mask blank to ensure an integrity mask/skin interface. In some embodiments, a mask blank may be shaped (for example, cutting the filter material) and/or formed to form an integrity mask/skin interface.

[0039] FIGS. 3A-3C depict an exemplary flat-fold dust mask. In FIG. 3A, an exemplary flat-fold mask 300 is depicted in a folded position. The flat-fold mask 300 may be opened when worn by a wearer, for example. In FIG. 3B, a front perspective view of an opened flat-fold mask 305 is depicted. When opened, the flat-fold mask may engage a wearer’s face. In FIG. 3C, a wearer 310 is depicted wearing an exemplary flat-fold mask 315. In the depicted embodiment, the flat-fold mask 315 vertically extends from a Sellion region 320 of the wearer 310 to a chin region 325 of the wearer 310. And the exemplary flat-fold masks horizontally extends from a left cheek 330 to a right cheek 335 of the wearer 310. In this way, the breathable mask fully encapsulates a wearer’s nose and mouth. Such encapsulation may ensure that air in an exterior atmosphere must transverse through the breathing mask before inhalation by the wearer 310. [0040] FIGS. 4A-4B depict an exemplary cup-shaped dust mask. In FIG. 4A, an exemplary cup-shaped breathing mask 400 is depicted from a perspective view. FIG. 4B depicts an exemplary cup-shaped breathing mask 405 being worn by a wearer 410. In the FIG. 4B depiction, the mask again completely covers a wearer’s mouth and nose. The breathing mask is depicted as being secured by straps that traverse behind a head and/or neck of the wearer 410 and connect to both a left and a right side of the breathing mask.

[0041] FIG. 5 depicts an exemplary breathing mask with an exemplary nose clip. In the FIG. 5 embodiment, an exemplary breathing mask 500 is depicted from a perspective view. The exemplary breathing mask 500 includes a nose clip 505. In some embodiments, the nose clip may be deformable. A deformable nose-clip may help to provide a custom seal around a portion of a wearer’s nose, for example. The nose clip may itself be customizable. For example, in some embodiments, the nose clip may be made longer or shorter, or the user might select from nose clip blanks of various sizes and/or shapes and/or materials. In some embodiments, the nose clip may be customizable and yet still deformable. In an exemplary embodiment, the nose clip may be custom formed to correspond to a nose bridge region of a wearers face. In some embodiments, the nose clip may be detachable from the mask. In some embodiments, the nose clip may be coupled to the breathing mask.

[0042] FIGS. 6A-6B depict exemplary breathing masks without nose clips. In the FIG. 6A embodiment, an exemplary breathing mask 600 that has no nose clip is depicted. In the depicted embodiment, the breathing mask 600 may be secured to a wearer’s face by coupling each of the two ear straps 605 about a wearer’s ears (although in other embodiments, a head strap or other means for attachment in place on a user’s face/head could be used). The ear straps 605 may include an elastic, for example. In some embodiments, the ear straps 605 may be customizable. For example, the ear straps (or head strap) 605 may have a customized length. A customization system may customize the length to correspond to dimensions of a wearer’s face. In some embodiments, the strength of the elastic may be customized based upon a user’s selection, for example. The depicted breathing mask 600 includes a filter portion 610. The size of the filter portion 610 may be customizable, for example. The type of filter material may be customizable in some embodiments. For example, various types of filter material may be selected by a wearer (for example, with different available mask blanks having different filtering capabilities (e.g. typically due to different filter materials, such that selection of a mask blank may result in selection of a specific filtering material)). In some embodiments, the filter material may be determined by the customization system to correspond with a particular atmospheric hazard. A user may also select from different combinations of filter materials. For example, different filter materials may provide different levels of protection.

[0043] In FIG. 6B, a breathing mask 615 may have a customizable sealing surface. The sealing surface elevation may be customizable around the sealing periphery. For example, a sealing surface may provide an integrity seal circumferentially around a wearer’s mouth and nose. Three dimensional facial elevation data may be used for customizing the sealing surface of the breathing mask 615. Such three dimensional elevation data may be obtained by various three dimensional imaging techniques described in“Virtual Mask Alignment for Fit Analysis,” (PCT/US2014/024098), for example. Exemplary methods for obtaining such three dimensional facial elevation data are described, for example, with reference to at least [0054, 0065 an 0081-0082] and FIG. 1 in patent application PCT/US2014/024098 titled“Virtual Mask Alignment for Fit Analysis,” filed on March 12, 2014, the entire disclosure of which is herein incorporated by reference.

[0044] FIGS. 7A-7C depict exemplary breathing masks with exemplary exhalation valves. In FIG. 7A, an exemplary breathing mask 700 having an exemplary exhalation valve 705 is depicted. The exhalation valve 705 may provide one-way fluid (e.g. air) transport from an interior side of the breathing mask to an exterior side of the breathing mask (while preventing entry of exterior, unfiltered air through the valve). Such an exhalation valve 705 may facilitate a user’s exhalation, for example. The exhalation valve 705 may reduce the resistance to exhalation that the filter may otherwise present to the user, for example. The exhalation valve 705 may direct the exhaled gases in a preferred direction. For example, the exhalation valve 705 may direct the exhaled gases away from a wearer’s eyes. Such a preferred direction may minimize the potential for moisture in the exhaled gases to condense on a wearer’s glasses, for example. 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, a user may select two or more exhalation valves, for example, one on either side of a user’s face. For example, an aperture size may be customizable. In some embodiments, a spring constant of a one-way control device may be customizable. And in some embodiments, the location of the exhalation valve on the mask may be customizable (for example, with the user selecting based on preference).

[0045] In FIG. 7B, an exemplary customizable mask 710 is depicted in perspective view. The customizable mask 710 has an exhalation member 715 coupled to the breathing mask 710. The exhalation cover 715 may be selectively attached to the breathing mask 710 based upon a user’s selection, for example. A mask-customization system may provide an integrity seal between the exhalation cover 715 and the breathing mask 710 during customization. In FIG. 7C, another exemplary breathing mask 720 with an exemplary exhalation valve 725 is depicted. The exhalation valve 725 may have a rigid or semi-rigid member 730 which may help maintain the shape of the mask, for example.

[0046] FIGS. 8A-8B depict exemplary breathing masks without exhalation valves. In the FIGS. 8A-8B embodiments, exemplary breathing masks 800, 805 have no exhalation valve. In some embodiments, other attachments may be customizable connected to a breathing mask. For example, in some embodiments, a chemical agent may be attached to a breathing mask (for example, with the kiosk automatically spraying chemicals onto the selected mask blank, or some of the mask blanks being pre-treated with chemicals, or with the kiosk attaching a sheet of pre-treated material to the mask blank, for example). In some embodiments, a user may select an air-hose coupling device to be attached to a mask. In such an embodiment, the air-hose coupling device may permit a supply of safe breathing air to be coupled to the breathing mask. In some embodiments, a scent (which might be perfume or aromatherapy) might be sprayed into the mask, for example based on user preference.

[0047] FIG. 9A depicts a block diagram of an exemplary mask customization system (for example, a kiosk or photo booth or vending machine device). In the FIG. 9A embodiment, a block diagram 900 of an exemplary mask customization system is shown coupled to an image-booth vending machine 905 (e.g. automated kiosk). The image booth vending machine 905 may have a camera 910 (or other image capture device) for obtaining facial image data corresponding to a user. A display device 915 may optionally display the captured facial image data. The display device may permit user input using a touch sensitive screen, for example (although in other embodiments, user input to the vending machine may be made using a keyboard, voice recognition, or other data input means). In some embodiments, the display screen 915 may provide instructions for the user. For example, the display screen 915 may provide instructions directing the user to turn the user’s face to the side for a side-view image capture. In some embodiments, the display screen 915 may direct the user to stand and/or sit at a specific location and/or to change orientation (e.g. direction being face), for example. 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 booth 905 may also have a mask modification module 920 for performing mask customization operations. The photo booth 905 may include a mask delivery port 925 where the customized mask in delivered to the user.

[0048] In FIG. 9A the block diagram 900 may represent the mask optimization control module, for example. The mask optimization control module 900 may include a processor 930 which is electrically coupled to the photo booth (or kiosk) 905, for example via an input/output port 935. The processor 930 may communicate with the mask modification module 920, the camera 910, and/or the display device 915. The processor 930 may send signals corresponding to display instructions for the user. The processor 930 may receive user inputs, for example from the touch sensitive display 915. The processor 930 may send instructions to operate the camera 910. The processor may receive, image data from the camera 910. The processor may send instructions to the mask modification module 920. The processor 930 may send image data to memory 940, after receiving the image data from the camera 910, for example. The processor 930 may perform operations to determine, from the image data, facial dimensions. The processor 930 may store and/or retrieve the determined facial dimensions into/from memory 945. The processor 930 may retrieve mask (blank) data from a mask database 950. The processor 930 may send image and/or mask data to a mask selection module 955. The mask selection module 955 may select a mask (blank) based upon the data sent to the mask selection module 955. The processor 930 may send image and mask data to a mask customization calculator 960. The mask customization calculator 960 may determine customization operations based upon the data sent to the mask customization calculator 960. The processor 930 may send signals/instructions corresponding the determined mask customization operations to the mask modification module 920 of the photo booth 905. The processor 930 may send signals/instructions corresponding to a user selected mask decoration to a mask decoration module 965 for example.

[0049] So, a typical mask customization system (for example of the type that might occur in a point-of-purchase or point-of-need vending machine, operable to offer semi- customized masks to better fit a particular user’s needs) might typically comprise a processor (or computer), a camera or other image scanner (e.g. image capture device), and a mask modification module operable to physically modify/customize a mask blank or template in accordance with instructions from the processor or computer. Typically, the processor would receive facial image data from the camera (e.g. image capture device), would process the facial image data to generate mask modification or customization instructions, and would then send those instructions to the mask modification module, which would operate automatically in accordance with the instructions to transform a mask blank into a semi- customized mask. Typically, the system might also comprise an exterior housing (similar to a vending machine or photo booth), which would house the camera and mask modification module, and which might also house the processor in some embodiments (although in other embodiments, the processor might be remotely located, and the housing might instead include a communication module (such as a wireless transmitter/receiver) allowing communication with the processor (for example, sending the camera facial image data to the processor, and then receiving the instructions from the processor to then provide to the mask modification module)). Some embodiments might also include an input device (for example, operable to allow a user to input user preferences, which might then contribute to either selection of the mask blank or generation of the mask modification instructions, and/or payment information (such as a credit card reader)) and/or an output device (for example for providing instructions to the user, for example with regard to orientation with respect to the camera). Exemplary input devices might be a keyboard or touchscreen or voice recognition, while exemplary output devices might be a display screen and/or speaker. Typically, the processor might receive preference or other user input data from the input device, and the processor might send instructions to the user (for example, for interaction with the camera) via the output device.

[0050] Once the processor has used the user input (for example regarding mask preferences) and/or facial image data (for example, facial measurements) to select a mask blank (typically selected from a plurality of mask blanks of various sizes, shapes, filtration capabilities, etc.) and generate mask modification or customization instructions and transmitted those instructions to the mask modification module, the mask modification module would typically operate automatically (e.g. in automated fashion) in accordance with those instructions (for example, selecting the chosen mask blank and applying one or more modification techniques to the mask blank in order to form a semi-customized mask in accordance with the instructions from the processor). Depending on the particular semi- custom mask vending machine (e.g. kiosk) embodiment, the amount of mask modification (and mask blank selectivity) available may vary. For example, FIG. 9B illustrates a basic mask modification module, in which a mask blank is selected from one or more (and typically a plurality of) racks 921b, with each rack having a different mask blank (for example, differing in size, shape, type (flat versus molded), filtering capabilities, and/or (ore- attached) features/elements (such as nose clip, head attachment system (e.g. strapping), exhalation valve, decorative cover, scent, and/or sealing section material or thickness)) than the other racks (and typically each rack would have a plurality of identical mask blanks, for example at least 10 of a specific mask blank in each rack), and then modified by cutting using a cutting element 926b. So in Fig. 9B, the mask modification module 920b comprises a plurality of racks 921b (each housing a plurality of a different mask blank), a transport mechanism 922b operable to transport the selected mask blank from the rack to the cutting element), a cutting element 926b operable to cut the mask blank according to the instructions to provide a better (semi-custom) fit for the user (for example, by cutting or trimming the perimeter of the mask blank), and a dispensing element 929b (which may be part of the transport mechanism) operable to dispense the finished semi-custom mask to the user. Such a mask modification module would allow for creation of a semi-custom mask (based on user facial image data and preferences) by selecting an appropriate mask blank from a plurality of options and then cutting the mask to help ensure a better fitting mask for the particular user (based, for example, on that user’s facial dimensions/image data). Since such a basic mask modification module typically would only cut or shape the mask blank, the various mask blanks would typically have any features or elements (such as strapping, sealing section material, exhalation valve, and/or nose clip) already attached to the initial mask blanks which are loaded into the racks (for example, having a plurality of racks, with each rack having a plurality of the same mask blank type, and each rack having a different mask blank type (for example, with differently sized and/or shaped mask blanks and/or having different features or elements pre-attached and/or having different mask blank categories (e.g. flat- fold and molded cup)). Typically, in the embodiment of Fig. 9B the strapping would be attached at a location on the mask blanks ensuring that it would not be cut off during the mask modification process, and the sealing section material would be pre-attached and would then be shaped by cutting of the mask blank (e.g. cutting both the filter material and the sealing section of the mask blank in a single step).

[0051] While the basic mask modification module of FIG. 9B would be capable of providing effective semi-custom masks to a user at the time and/or location of need, some mask modification module embodiments might provide even more customization. FIG. 9C illustrates a premium mask modification module 920c, which may allow for further customization of the mask to the particular user’s preferences and/or needs and/or face. For example, the mask modification module 920c of FIG. 9C comprises one or more (and typically a plurality of) racks 921c (with each such rack typically holding a plurality of a particular mask blank, and each rack having a different mask blank than the other racks), a heat mold 923c (which may form and/or shape the mask blank), a cutting element 926c (operable to cut the mask blank according to instructions from the processor), and an attachment device 927c (operable to attach one or more element or feature to the mask), which typically would work in conjunction with a storage unit for each of the various elements or features which may optionally be attached to the mask (for example, strapping S, nose clips N, exhalation valves V, decorative covers D, and/or sealing foam or other sealing material F). Additionally, the mask modification module 920 of FIG. 9C typically might also comprise a transport mechanism or system 922c (operable to move the mask blank within the module, for example from the rack to the mold to the cutting device and/or to the attachment device), which may also include a dispensing element 929c (for dispensing the mask to the user, although in some embodiments the dispensing element may be a separate element). In some embodiments, cutting/shaping and attachment might occur in the same location, for example with robotic arms bringing the various devices to the mask blank at a single location/work station (such that there may not be any transport system, or the transport system might only move the mask blank from the rack to a single station and/or from the station to dispensing, for example into a slot for pick-up by the user). Depending on the instructions from the processor, any or all of the parts of the automated mask modification module 920c might be used to automatically create a semi-custom mask.

[0052] FIG. 9D illustrates in more detail an exemplary (premium) mask modification module 920d. In FIG. 9D, the transport system comprises one or more conveyor belts 922d operable to move a mask blank selected or dispensed from a rack 921d (and typically there may be a plurality of racks from which to select a mask blank) between stations (although in other embodiments, there may be no need for transport between work stations, for instance with the mask blank staying in one location/station during formation (e.g. shaping and attachment) and different robotic arms (or a single robotic arm capable of multiple functions) performing the various required modifications). An optional heated mold 923d (which may help form/shape the mask in some embodiments) may comprise a robot arm to help transition the mask blank between conveyor belts. And in some embodiments, there may be a plurality of molds 923d, with the specific mold for a particular mask formation process being selected automatically based on instructions from the processor. A cutting device (such as a laser or cutting blade) 926d may automatically modify the mask blank in accordance with instructions from the processor (for example, cutting the perimeter to better fit user facial contours and/or cutting a hole for attachment of an exhalation valve), and an attachment device (such as an adhesive applicator or ultrasonic welder or stapler, for example) 927d may then automatically attach one or more elements (such as strapping, etc.) to the mask blank. In FIG. 9D, the attachment device would be located on a robotic arm, and would include an integrated strap feeding mechanism (for example, automatically dispensing strapping from a spool in proximity to the attachment device (such as an adhesive applicator and/or (ultrasonic) welder and/or stapler) in order to attach strapping in a single step. The end of the conveyor belt system 922d may then serve as the dispensing element 929d (for example, dropping via gravity the finished mask into a pick-up hopper/slot 925d).

[0053] Persons of skill should understand that when a basic mask modification module (such as that shown in FIG. 9B for example) is used, the mask blanks typically may be more complete to start with (for example, already having strapping attached in 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 such as foam attached about the perimeter of the mask blank (such that only excess sealing section might be cut off from the mask blank during customization). In other words, a basic mask modification module may have one or more elements/features pre-attached to various masks blanks. Also, the racks may hold mask blanks with different filtration levels. In a more premium model (such as that shown in FIG. 9C), initial mask blanks in the rack may be more basic (for example, not having strapping, nose clip, valve, decorative cover, and/or sealing material attached to start with, but rather adding the specific features or elements during mask modification (e.g. the semi- customization process) to provide a more customized mask). In some embodiments, the mask blanks might only vary by filtration level or material, size, shape, and/or type/category (e.g. flat-fold or molded cup), and might not have any other features pre-attached (except perhaps sealing section material in some embodiments). Some embodiments might have only flat mask blanks initially, and use a heat mold if a molded cup mask is desired, although other embodiments might have racks with both flat and molded cup mask blanks. Additionally, some embodiments may allow the user to select from a plurality of options with respect to each feature or element that may be added to the mask blank. For example, there may be a plurality of storage bins each holding a different nose clip, a plurality of storage bins each holding a different exhalation valve, a plurality of storage bins each holding a different decorative cover (which may optionally be attached to the exterior of the mask), a plurality of storage bins each holding a different sealing section material (e.g. different type, size, or shape of material), and/or a plurality of storage bins each holding a different strapping/head-attachment system. So for example, in some embodiments the processor might select sealing material and send attachment instructions (including location for attachment, for example 5 mm from one or more of the mask’s edges) to the mask modification module. Additionally, in some embodiments, the user might be able to select the location of the exhalation valve, with the cutting element 926c then cutting a hole (of the appropriate size and/or shape for the selected valve) at the selected location and the attachment device 927c attaching the selected valve over the cut hole. 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. may include or exclude any of them). So for example, an intermediate mask modification module might already have blanks with sealing section, nose clips, and/or valves pre-attached, and might add (for example, via the attachment device) the strapping and/or decorative cover (and/or scent or chemical spray) to the selected mask blank after cutting. The precise amount of mask customization available from any specific vending machine may depend on business or marketing decisions.

[0054] Methods for on-site (e.g. in situ) real-time (e.g. substantially immediately after ordering and/or instructing formation/customization of the mask and/or substantially immediately before dispensing the mask) semi-custom mask formation and dispensing (for example at the point and time of purchase) have been discussed above to some degree with respect to specific vending machine/kiosk embodiments. Alternate method embodiments for formation of semi-custom breathing masks (for example in real-time and/or in situ) may include one or more of the following steps: obtaining facial image data of a user’s face (which typically might be 3D image data), for example front and side views, taken by a camera or other image capture device; extracting facial details and/or measurements from the facial image data; optionally obtaining user preference information (which might include preferred mask type and/or features and/or filtration needs and/or scent preference, for example via an input device); selecting a mask blank from a plurality of different available mask blanks (which in some embodiments might also include providing a plurality of different mask blanks) based on the facial image data and/or preferences (e.g. automatically based on instructions from a processor which are based on image data and/or preferences); modifying/customizing the selected mask blank based on the facial image data (e.g. automatically based on instructions from a processor which are based on image data and/or preferences); and/or dispensing the finished semi-custom mask to the user (e.g. automatically in real-time). Typically, such methods might be performed automatically, for example using an automated vending machine or kiosk at the point-of-purchase and/or in proximity to the site of use for the semi-custom mask and/or in real-time (for example, substantially immediately after the user orders/purchases the semi-custom mask, which might for example mean that the kiosk begins the process of semi-custom mask formation immediately, such that the delay between ordering/payment for the mask and dispensing the mask to the user might merely be the amount of time that the semi-custom mask formation process takes to occur). Typically, the actual physical mask formation of such a process might occur on-site (e.g. the site of purchase and/or in proximity to the site of use) within the kiosk (for example, within the housing for the kiosk/vending machine). Also, the mask modification module and image capture device typically would be located within the same housing (e.g. within a kiosk housing and/or at the same location). Typically, the automated process may occur with the processor taking any user preferences and/or payment and then automatically controlling the image capture device, with the processor then taking the 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 automated formation and dispensing of the semi-custom mask. Thus, the mask modification module would typically operate its steps in automated fashion, automatically implementing the instructions from the processor (for example, to select the mask blank and customize it).

[0055] In some method embodiments, the mask modification/customization might include one or more of the following: cutting the selected mask blank according to the instructions from the processor, heat molding the mask blank in accordance with the instructions from the processor, attaching strapping to the selected mask blank according to the instructions from the processor (which in some embodiments might include selecting a strapping from a plurality of different available straps for attachment of the mask to the user’s face/head and/or attaching the strapping at the desired location and/or in the desired manner (e.g. forming ear straps or a head strap, which might be customized in length)), attaching a nose clip to the selected mask blank according to the instructions from the processor (which in some embodiments might include selecting a nose clip from a plurality of different available nose clips), cutting a hole and/or attaching an exhalation valve to the selected mask blank in accordance with instructions from the processor (which in some embodiments might include selecting a valve from a plurality of different available valves), and/or attaching sealing material to and/or cutting sealing material from the selected mask blank (which in some embodiments might include selecting sealing material from a plurality of different available sealing materials). Some method embodiments might also include automatically spraying, for example a chemical or scent, onto the mask, for example based on user preferences, in accordance with instructions from the processor. The mask blanks available may include one or more flat-fold mask blanks and/or one or more molded cup mask blanks. And in some embodiments, one or more of the available mask blanks (for example, in the racks) may include one or more of the following features/elements pre- attached to the mask blank filter material: an exhalation valve, strapping, sealing material/section, a nose clip, and/or a decorative cover. In embodiments in which one or more feature/element is pre-attached, the mask modification/customization instructions typically ensure that any cutting or other removal of filter or mask blank material will not result in removal of the pre-attached feature(s)/element(s). Persons of skill should understand that these disclosed methods embodiments may be used with (and relate to) any of the disclosed kiosk/vending machine devices described herein for formation of any described mask embodiments described herein. In other words, such exemplary methods/processes might be performed using one or more of the device embodiments described herein (e.g. figure embodiments above and/or additional embodiments below, with specific method steps relating to those device elements/components being employed herein).

[0056] FIG. 10 depicts a flow chart that describes an exemplary method of obtaining facial metrics from image data. FIG. 10 depicts and exemplary method of obtaining facial metrics 1000 from the perspective of the processor 930 of the block diagram depicted in FIG. 9. The method 1000 begins with the processor 930 receiving facial image data 1005. The processor 930 then initializes a counter, i 1010. The processor 930 then performs operations to locate an i^th feature in the image data 1015. For example, the processor 930 may determine a location of a nose and/or mouth (for example, using facial recognition technology). The processor 930 then determines one or more measurements corresponding to the located feature 1020. The processor 930 then increments the counter, i 1025. The processor 930 compares the incremented counter, i, with a predetermined maximum count, i_max 1030. If the counter, i, is less than the maximum count, i_max, then the processor 930 returns to step 1005 and locates the new i^th feature in the image. If, however, the count, i, is greater than the maximum count, i_max, then the processor 930 stores the measurement results obtained at step 1020 into memory locations 1035.

[0057] FIG. 11 depicts a flow chart that describes an exemplary method of selecting a mask for use for customization. FIG. 11 depicts and exemplary method of selecting a mask for use for customization 1100 from the perspective of the processor 930 of the block diagram depicted in FIG. 9. The method begins with the processor 930 retrieving measurement data from memory 1105. For example, the processor 930 may retrieve the measurement data stored in memory at step 1035 of the method depicted in FIG. 10. The processor 930 then initializes a counter, m 1110. The processor 930 then retrieves a mask customizable feature data corresponding to a mask that will be customized 1115. The processor 930 then calculated, based upon the received measurement data and the retrieved mask customizable feature data, the needed modifications to perform 1120. The processor 930 then increments the counter, m 1125. The processor 930 then compares the counter with a predetermined maximum count, m_max 1130. If the counter, m, is not greater than the maximum count, m_max, then the processor 930 returns to step 1115 and retrieves the mask customizable feature data corresponding to the new count, m. If, however, the counter, m, is greater than the maximum count, m_max, then the processor 930 sorts the calculated modification data from masks requiring the least modification to those requiring the most modification 1135. Then the processor 930 selects the mask requiring the least modification 1140. The processor 930 then retrieves the mask data corresponding to the selected mask 1145. Then the processor 930 sends, to a mask selection engine, modification instructions corresponding to the mask modifications needed for the selected mask 1150.

[0058] FIG. 12 depicts a flow chart that describes an exemplary method for customizing a mask for a user. FIG. 12 depicts and exemplary method of customizing a mask for a user 1200 from the perspective of the processor 930 of the block diagram depicted in FIG. 9. The method begins with the processor 930 initializing a counter, n 1205. The processor 930 then retrieves a mask’s feature data corresponding to the index of the counter, n 1210. Then the processor 930 retrieves measurement data corresponding to a specific measurement of the facial feature corresponding to the index, n 1215. The processor 930 then compares the facial measurement to the mask feature corresponding to the index, n 1225. If the measurement data is larger than the mask feature, then the processor 930 determines if the mask can be modified to accommodate this negative difference 1235. Similarly, if the measurement data is smaller than the mask data, the processor 930 determines if the mask can be modified to accommodate this positive difference 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 masks cannot be modified or after the modification instructions have been sent to the modification engine, the processor 930 increments the counter, n 1250. The processor 930 then compares the counter, n, with a maximum count, n_max 1255. If the counter, n, is less than or equal to the maximum count, n_max, then the processor 930 returns to step 1210 and retrieves the next mask feature data corresponding to the incremented index, n. If however, the counter, n, is greater than the maximum count, n_max, then the method ends.

[0059] In some embodiments fit data for a sealing interface between a mask and a wearer’s face may be used to determine a quality of a fit. Exemplary methods of determining fit quality based upon a sealing interface are described, for example, with reference to at least [page 3 line 28 through page 5 line 29] and FIG. 1 in US patent application 13/839,056 titled“System and Method for Selecting a Respirator,” filed on March 15, 2013, the entire disclosure of which is herein incorporated by reference.

[0060] In some embodiments an internal volume between a mask and a wearer may be calculated to determine a quality of fit. Exemplary methods of determining fit quality based upon an internal volume are described, for example, with reference to at least [page 16 line 27 through page 17 line 8] and FIG. 7 in US patent application 13/839,186 titled “System and Method for Selecting a Respirator,” filed on March 15, 2013, the entire disclosure of which is herein incorporated by reference.

[0061] In some embodiments, a fit quality metric of a mask may be determined base, at least in part, by assigning semantic information to a series of points of a mask model. Exemplary methods of determining a quality of fit based upon such a method are described, for example, with reference to at least [page 1 line 22 through page 2 line 33] and FIG. 1 in US patent application 61/814,897 titled“System and Method for Selecting PPE,” filed on April 23, 2013, the entire disclosure of which is herein incorporated by reference.

[0062] In some embodiments, a graphical user interface may be used to display fit quality metrics to a user. Exemplary graphical display images are described, for example, with reference to at least FIGS. 1-5 in US patent application 61/814,905 titled“System and Method for Evaluating PPE Fit,” filed on April 23, 2013, the entire disclosure of which is herein incorporated by reference. In some embodiments, the vending machine (via the graphical user interface, for example) might provide the user with one or more mask recommendations (for example, recommending a mask blank and one or more additional elements), for example, based on quality fit metrics and/or inputted user preferences. And in some embodiments, the vending machine (via the graphical user interface, for example) might also base recommendations off of current atmospheric conditions locally (for example, perhaps sensing atmospheric quality and/or receiving a report of atmospheric quality from a remote sensor, and then determining the best mask (or ranking mask effectiveness) based on those atmospheric conditions).

[0063] In some embodiments, a graphical user interface may be used to provide a user interface between a mask fitting system and a user. Exemplary methods of performing such graphical user interfaces are described, for example, with reference to at least [0021- 0022] and FIGS. 1-2 in US patent application 61/861,294 titled“Virtual Mask Fitting System,” filed on August 1, 2013, the entire disclosure of which is herein incorporated by reference.

[0064] In some embodiments a method of virtually fitting a mask model to a wearer’s face may be performed by first performing a virtual fit of a chin region and then virtually rotating the mask model toward or away from the virtual face to fit a nose-bridge region. Exemplary methods of performing such a virtual fit are described, for example, with reference to at least [0030-0031] and FIGS. 7-8 in US patent application 61/917,171 titled “Virtual Mask Alignment for Fit Analysis,” filed on December 17, 2013, the entire disclosure of which is herein incorporated by reference. [0065] Having described above various product/apparatus/system and method/process embodiments (especially those shown in the figures), various additional embodiment may include, but are not limited to the following:

[0066] In a first embodiment, an (on-site) (semi-custom (e.g. customized/personalized)) breathing (e.g. dust) mask dispensing device (e.g. a vending machine, photo booth, or kiosk for customizing the breathing mask to a particular user), comprising: an image capture device (such as a camera or 3-D facial scanner)(for example, operable to capture 3-D facial image data from a user (which might require multiple uses of the camera when the user is oriented/positioned differently (for example front and side views))); a mask modification module (housing a plurality of (different) mask blanks and) operable to transform mask blanks into semi-custom masks (e.g. personalized/customized for the user); and a processor (or mask optimization control module) operable to use the image data from the image capture device to generate instructions to the mask modification module regarding creation of a semi-custom mask from the available mask blanks (for example, sending mask blank selection instructions so the mask modification module selects the appropriate mask blank for modification and sending mask customization instructions (e.g. operations) so the mask modification module appropriately customizes/modifies the selected mask blank). In a second embodiment, the device of embodiment 1 further comprising a (vending machine) housing encompassing 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 (vending machine) locations (e.g. the vending machine may be transported as a whole unit between locations and easily/conveniently set-up– for example simply by plugging into electrical power socket) (wherein the housing may be located at point-of-purchase locations and provide a semi-custom mask to a user in real time (e.g. with only a short delay (for example due to immediate mask formation), for example about 25 seconds, less than two minutes, less than one minute, less than 30 seconds, or 25 seconds or less between the customer ordering 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 might be remotely located but in communication with (e.g. via wireless transmission with a wireless transmitter and/or receiver located within the housing) the image capture device and mask modification module within the housing at the point-of-purchase site). In a fourth embodiment, the device of embodiments 1-3 further comprising an input device operable to receive information from the user (for example, personal preference information and/or payment information) and transmit the user information to the processor (with such user information perhaps being used to aid in selection of the mask blank or the mask customization (e.g. the personal preference information may be used in generating the selection instructions and/or the customization instructions)). In a fifth embodiment, the device of embodiment 1-4 further comprising an output device operable to allow the processor to communicate with the user (e.g. in communication with the processor to provide instructions to the user, for example about positioning for image capture and/or displaying mask preference selections). In a sixth embodiment, the device of embodiments 1-5 wherein the mask modification module further comprises: one or more racks, with each one of the racks holding a plurality of identical mask blanks, and each of the mask racks holding a different type of mask blank (e.g. different mask blank sizes, shapes, and/or category (e.g. flat-fold or molded cup) and/or pre- mounted feature(s) (e.g. nose clip, strapping mechanism, exhalation valve, etc.) and/or filtration level) from the other racks of mask blanks, wherein the one or more racks are operable to hold and dispense mask blanks for customization (for example, upon receiving (mask blank selection) instructions from the processor or mask optimization control module); and a mask modification element (for example, operable to modify (for example the size and/or shape of) the selected mask blank in accordance with the mask customization instructions from the processor). In a seventh embodiment, the device of embodiment 6 wherein the mask modification element is a cutting element (such as a blade or laser cutter, which might optionally be located on a robotic arm or gantry operable to move/reposition the cutter) and/or a heated mold (operable for stamping of the mask blank). In an eighth embodiment, the device of embodiment 6-7 wherein the mask modification module further comprises a dispensing mechanism (for example, gravity-fed hopper off a conveyor belt, etc.) operable to dispense the completed/finished semi-custom mask to the user (for example upon completion of operation of the mask modification element). In a ninth embodiment, the device of embodiment 6-8 wherein the mask modification module further comprises a transport mechanism (e.g. conveyor belt(s) or robotic arm(s)) operable to move the selected mask blank at least from the rack, to the mask modification element, and/or then to the dispensing mechanism (and wherein in some embodiments, the dispensing mechanism is part of the transport mechanism). In a tenth embodiment, the device of embodiments 6-9 wherein the mask modification module a restraining mechanism (for example, with mechanical restraints or vacuum suction) operable to securely hold the selected mask blank in position/place during mask modification (for example during cutting by the cutting element)(and in some embodiments, the restraining mechanism may be part of the transport mechanism/system– for example restraining clips on a conveyor belt). In an eleventh embodiment, the device of embodiment 6-10 wherein the mask modification module further comprises an attachment device/mechanism operable to (permanently) attach one or more (optional) features or elements (for example, strapping, nose clip, exhalation valve, decorative cover, and/or sealing section material/foam) to the mask blank (in accordance with the mask customization instructions). In a twelfth embodiment, the device of embodiment 11 wherein the attachment device further comprises one or more storage elements/bins/racks holding the optional feature/element components available for selection (in accordance with the selection instructions from the processor) and attachment (according to the mask customization instructions from the processor) to the mask blank. In a thirteenth embodiment, the device of embodiment 11-12 wherein the attachment device further comprises an adhesive applicator or welding device (for example ultrasonic welder) (which may optionally be mounted on a robotic arm or gantry operable to position or move the attachment device). In a fourteenth embodiment, the device of embodiment 11-13 wherein the attachment device further comprises a spool of strapping attached to the attachment device and operable to automatically dispense strapping for attachment to the mask blank (e.g. in accordance with mask customization instructions from the processor). In a fifteenth embodiment, the device of embodiments 11-14 wherein the mask customization instructions include instructions regarding selection of optional features/elements for inclusion on the semi-custom mask (and optionally may also include location/positioning instructions for one or more of the selected optional features/elements). In a sixteenth embodiment, the device of embodiment 1-15 wherein the device is operable to provide a semi-custom mask to a user at the point-of-purchase in real-time (e.g. the mask is made from a mask blank at the point-of- purchase at the time of purchase) (for example based on the user’s facial image data and/or personal preference information) (and/or wherein the device is operable to be moved as a whole/integrated unit to another location and/or the housing is sized to have a footprint less than or equal to typical vending machine or photo booth size, for example less than about 61 inches width by 40 inches depth, less than about 45 inches width by 40 inches depth, about 45 inches wide by 40 inches deep, about 1.1 meter wide by 0.9 meter deep, about 57 inches wide by 29 inches deep, about 61 inches wide by 39 inches deep, or about 39 inches by 33 inches, so the device can be used at typical vending machine locations). In a seventeenth embodiment, the device of embodiments 1-16 wherein the mask blank selection instructions generated by the processor use the measured facial dimension/image data to select a mask blank according to five basic demographic face shapes (e.g. long-narrow, small, medium, large, and short-wide). In an eighteenth embodiment, the device of embodiments 1-17 wherein the mask customization instructions generated by the processor use a surface flattening mechanism to modify the measured facial dimension/image data in order to then create cutting instructions (for example for a flat-fold-type mask blank). In a nineteenth embodiment, the device of embodiment 1-18 wherein the processor/ mask optimization control module comprises one or more of the following: a mask blank selection module, a mask blank customization calculator/module, a mask decoration module, and/or memory storage regarding facial image data storage, critical dimension data storage, and/or mask database). In a twentieth embodiment, the device of embodiments 1-19 wherein instructions from the processor comprise signals (for example, transmitted via wiring or wirelessly). Ina twenty-first embodiment, the device of embodiments 1-20 wherein instructions from the processor (e.g. mask blank selection instructions and/or mask customization instructions) to the mask modification module are based on one or more of the following measured facial image data: bizygomatic breadth, bigonial breadth, nose-protrusion distance, nose breadth, lip length, Subnasal Sellion length, Menton-subnasal length, depth of face, Tragion-subnasal arc, Tragion-menton arc, and Menton-Sellion length (e.g. when the processor extracts these measurements from the facial image data sent from the image capture device). In a twenty- second embodiment, the device of embodiments 12-21 wherein the storage bins comprise a plurality of nose clip bins, with each one of the plurality of bins having a differently sized and/or shaped and/or material of nose clip from the other bins of nose clips, and with each particular bin of nose clips having a plurality of identical nose clips (for example, bin A having only A-type nose clips, and none of the other bins having A-type nose clips; bin B having only B-type nose clips, and none of the other bins having B-type nose clips, etc.). In a twenty-third embodiment, the device of embodiments 12-22 wherein the storage bins comprise a plurality of exhalation valve bins, with each one of the plurality of bins having a different type of exhalation valve from the other bins of exhalation valves, and with each particular bin having a plurality of identical exhalation valve (for example, bin A having only A-type valves, and none of the other bins having A-type valves; bin B having only B- type valves, and none of the other bins having B-type valves, etc.). In a twenty-fourth embodiment, the device of embodiments 12-23 wherein the storage bins comprise a plurality of decorative cover bins, with each one of the plurality of bins having a different type of decorative cover from the other bins of decorative covers, and with each particular bin having a plurality of identical decorative covers (for example, bin A having only A-type decorative covers, and none of the other bins having A-type decorative covers; bin B having only B-type decorative covers, and none of the other bins having B-type decorative covers, etc.). In a twenty-fifth embodiment, the device of embodiments 12-24 wherein the storage bins comprise a plurality of strapping bins (which could be rolls, etc.), with each one of the plurality of bins having a different type of strapping from the other bins of strapping, and with each particular bin having a plurality of identical strapping (for example, bin A having only A-type strapping, and none of the other bins having A-type strapping; bin B having only B-type strapping, and none of the other bins having B-type strapping, etc.). In a twenty-sixth embodiment, the device of embodiments 12-25 wherein the storage bins comprise a plurality of sealing material bins, with each one of the plurality of bins having a different type (including material, size, and/or shape) of sealing material from the other bins of sealing materials, and with each particular bin having a plurality of identical sealing materials (for example, bin A having only A-type sealing material, and none of the other bins having A-type sealing material; bin B having only B-type sealing material, and none of the other bins having B-type sealing material, etc.). In a twenty-seventh embodiment, the device of embodiments 12-25 wherein the storage bins are operable to automatically dispense the appropriate feature/element from the one or more storage bins in response to instructions (e.g. mask customization instructions) from the processor (for example, with the dispensed feature/element then being positioned relative to the mask blank and fixed to the mask blank using the attachment mechanism). In a twenty-eighth embodiment, the device of embodiment 1-27 wherein the mask customization instructions include instructions to cut/form a hole in the mask (perhaps at a selected location based for example on user preference) for interaction with a selected/dispensed exhalation valve (for example, with the attachment mechanism attaching the exhalation valve over the formed hole in a sealing manner). In a twenty-ninth embodiment, the device of embodiments 1-28 wherein the semi- custom mask is formed in-situ at the location of the vending machine (e.g. the housing or the point-of-purchase or point-of need) and/or formed in-situ in real time (for example, in proximity to the time of order and/or purchase and/or dispensing to the user/customer). In a thirtieth embodiment, the device of embodiment 1-29 wherein the device further comprises sensors (typically located on the housing) operable to detect air conditions (for example, pollution levels and/or contaminants) and to recommend mask features based on the sensed data (e.g. with the processor communicating with the user via the output device). In a thirty- first embodiment, the device of embodiment 6-30 wherein the racks of mask blanks may comprise mask blanks of different filtering capabilities (so for example the user may select the level of breathing protection desired/required). In a thirty-second embodiment, the device of embodiment 6-31 wherein the racks have mask blanks with one or more features/elements/accessories pre-attached to the filtration material. In a thirty-third embodiment, the device of embodiment 6-32 wherein the racks have at least 5 (for example, one mask blank for each of the five standard demographic facial types), at least 10, 10-20, 10-50, 15-20, or 20-50 different mask blanks available (e.g. different sizes, shapes, categories (e.g. flat-fold or molded cup), filtration capabilities, and pre-attached accessories/features/elements of mask blanks) (and/or wherein each rack typically has at least 10, 10-20, 10-50, 15-20, or 20-50 identical mask blanks). In a thirty-fourth embodiment, the device of embodiment 1-33 wherein the device further comprises a transmitter operable to signal (for example sending an electronic message to a central station for maintenance of a plurality of such vending machines) when the device needs restocking with mask blanks and/or features/elements/accessories, and/or need maintenance or repair). In a thirty-fifth embodiment, the device of embodiment 13-34 further comprising a mask cooling mechanism (for example, a fan) operable to cool the finished semi-custom mask prior to dispensing to a user (for example, to ensure that the adhesive is not so hot that it might burn a user and/or to ensure that the adhesive has solidified attachment sufficiently and/or more quickly). Persons of skill will understand that several of the disclosed embodiments may be similar, such that descriptions attributed to a particular embodiment may also apply for other, similar embodiments. [0067] While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features or steps of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

[0068] Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a“Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the“Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to“invention” in the singular should not be used to argue 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), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

[0069] Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Use of the term“optionally,”“may,”“might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

[0070] 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, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

[0071] Also, 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. A number of implementations have been described. Nevertheless, it will be understood that various modification may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with 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

CLAIMS What is claimed is:

1. A device comprising:

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

a mask modification module operable to transform mask blanks into semi-custom masks; and

a processor operable to use the image data from the image capture device to generate instructions to the mask modification module regarding creation of a semi-custom mask from available mask blanks;

wherein the mask modification module automatically transforms mask blanks in accordance with instructions from the processor.

2. The device of claim 1 further comprising a kiosk housing encompassing 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 locations.

3. The device of claim 1 further comprising:

an input device operable to receive information from the user and transmit the user information to the processor; and

an output device operable to allow the processor to communicate with the user.

4. The device of claim 1 wherein the mask modification module further comprises: one or more racks, with each one of the racks holding a plurality of identical mask blanks, and each of the mask racks holding a different type of mask blank from the other racks of mask blanks, wherein the one or more racks are operable to hold and automatically dispense mask blanks for customization upon receiving instructions from the processor; and a mask modification element operable to modify a selected mask blank in accordance with the instructions from the processor.

5. The device of claim 4 wherein the mask modification element comprises a cutting element and/or a heated mold.

6. The device of claim 5 wherein the mask modification module further comprises a transport mechanism operable to move the selected mask blank at least from the rack to the mask modification element.

7. The device of claim 4 wherein the mask modification module further comprises an attachment mechanism operable to automatically attach one or more feature to the selected mask blank in accordance with instructions from the processor).

8. The device of claim 7 wherein the attachment device further comprises one or more storage elements holding feature components available for selection and attachment to the selected mask blank.

9. The device of claim 7 wherein the attachment device further comprises an adhesive applicator or welding device.

10. The device of claim 8 wherein the instructions from the processor include instructions regarding selection of features for inclusion on the semi-custom mask.

11. The device of claim 1 wherein the instructions generated by the processor use the facial image data to select a mask blank according to five basic demographic face shapes.

12. The device of claim 1 wherein instructions from the processor to the mask modification module are based on one or more of the following facial image data: bizygomatic breadth, bigonial breadth, nose-protrusion distance, nose breadth, lip length, Subnasal Sellion length, Menton-subnasal length, depth of face, Tragion- subnasal arc, Tragion-menton arc, and Menton-Sellion length (e.g. when the processor extracts these measurements from the facial image data sent from the image capture device).

13. The device of claim 8 wherein the storage elements comprise a plurality of nose clip storage elements, with each one of the plurality of nose clip storage elements having a differently sized and/or shaped and/or material of nose clip from the other storage elements of nose clips, and with each particular storage element of nose clips having a plurality of identical nose clips; and wherein the storage elements further comprise a plurality of exhalation valve storage elements, with each one of the plurality of exhalation valve storage elements having a different type of exhalation valve from the other storage elements of exhalation valves, and with each particular exhalation valve storage element having a plurality of identical exhalation valves.

14. The device of claim 4 wherein the racks of mask blanks comprise mask blanks of different filtering capabilities.

15. The device of claim 4 wherein the racks comprise mask blanks with one or more feature pre-attached to mask blank filtration material.