Custom fitted mask and method of forming same

1. A mask blank for using in forming a custom fitted mask, comprising a thin sheet of deformable material having a perimeter, the perimeter defining a first portion of a generic user'face to include only soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose and to exclude hard bony portions of the generic user's nose generally above the soft cartilaginous portions of the generic user's nose;

wherein the thin sheet of deformable material is adapted to be:

transitioned from a non-deformable state into a deformable state;

applied against at least a first portion of a particular user's face surrounding the particular user's nostrils while the mask blank is in the deformable state; and

deformed against the first portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask; and

wherein:

the thin sheet of deformable material includes a depression sufficient to accommodate at least a portion of the generic user's nose surrounding the generic user's nostrils;

the thin sheet of deformable material is substantially flat on either side of and below the depression; and

the thin sheet of deformable material is adapted to be deformed against at least a first portion of the particular user's face surrounding the user's nostrils.

2. The mask blank of claim 1 , further adapted to be:

applied against at least a second portion of the particular user's face surrounding the particular user's mouth while the mask blank is in the deformable state; and

deformed against the second portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask.

3. The mask blank of claim 2 , wherein the mask blank comprises a first portion for applying to the first portion of the particular user's face and a second portion for applying to the second portion of the particular user's face, the first portion of the mask blank adapted to be coupled to the second portion of the mask blank in forming the custom fitted mask.

4. The mask blank of claim 2 , further adapted to be:

applied against at least a third portion of the particular user's face under the user's chin while the mask blank is in the deformable state; and

deformed against the third portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask.

5. The mask blank of claim 3 , wherein the mask blank comprises a first portion for applying to the first portion of the particular user's face and a second portion for applying to the second and third portions of the particular user's face, the first portion of the mask blank adapted to be coupled to the second portion of the mask blank in forming the custom fitted mask.

6. The mask blank of claim 1 , wherein the mask blank comprises an injection molded mask blank.

7. A mask blank for using in forming a custom fitted mask, comprising:

a thin sheet of deformable material having a perimeter, the perimeter defining a first portion of a generic user's face to include only soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose and to exclude hard bony portions of the generic user's nose generally above the soft cartilaginous portions of the generic user's nose;

wherein the thin sheet of deformable material:

includes a depression sufficient to accommodate at least a portion of the generic user's nose surrounding the generic user's nostrils;

is substantially flat on either side of and below the depression; and

is adapted to be:

transitioned from a non-deformable state into a deformable state;

applied against at least a first portion of a particular user's face surrounding the particular user's nostrils while the mask blank is in the deformable state; and

deformed against the first portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask; and

holes, one for each of the generic user's nostrils, adapted to receive fittings for coupling the custom fitted mask to an external gas supply system.

8. A mask blank for using in forming a custom fitted mask, comprising:

a thin sheet of deformable material having a perimeter, the perimeter defining a first portion of a generic user's face to include only soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose and to exclude hard bony portions of the generic user's nose generally above the soft cartilaginous portions of the generic user's nose;

wherein the thin sheet of deformable material:

includes a depression sufficient to accommodate at least a portion of the generic user's nose surrounding the generic user's nostrils;

is substantially flat on either side of and below the depression; and

is adapted to be:

transitioned from a non-deformable state into a deformable state;

applied against at least a first portion of a particular user's face surrounding the particular user's nostrils while the mask blank is in the deformable state; and

deformed against the first portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask; and

holes for receiving devices for coupling the custom fitted mask to one or more straps for securing the custom fitted mask to the particular user's face.

9. A mask blank for using in forming a custom fitted mask, comprising a thin sheet of deformable material having a perimeter, the perimeter defining a first portion of a generic user's face to include only soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose and to exclude hard bony portions of the generic user's nose generally above the soft cartilaginous portions of the generic user's nose;

wherein the thin sheet of deformable material:

includes a depression sufficient to accommodate at least a portion of the generic user's nose surrounding the generic user's nostrils;

is substantially flat on either side of and below the depression; and

is adapted to be:

transitioned from a non-deformable state into a deformable state;

applied against at least a first portion of a particular user's face surrounding the particular user's nostrils while the mask blank is in the deformable state; and

deformed against the first portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask; and

wherein the deformable material comprises a thermoplastic polymer and the mask blank must be heated to transition the mask blank into the deformable state.

10. The mask blank of claim 9 , wherein the thermoplastic polymer comprises a polycaprolactone polymer.

11. The mask blank of claim 9 , wherein the custom fitted mask when in use is adapted to cover a portion of the particular user's face surrounding the particular user's nostrils, the portion of the particular user's face comprising only soft cartilaginous portions of the particular user's nose and portions of the particular user's face on either side of and below the soft cartilaginous portions of the particular user's nose but does not cover hard bony portions of the particular user's nose generally above the soft cartilaginous portions of the particular user's nose.

12. The mask blank of claim 9 , wherein the custom fitted mask comprises a mask for use in treating sleep disordered breathing.

13. A mask blank for using in forming a custom fitted mask for treating sleep disordered breathing, the mask blank comprising:

a thin sheet of deformable thermoplastic polymer material contoured in the shape of a portion of a generic user's face surrounding the generic user's nostrils, the thin sheet of deformable material comprising:

a perimeter defining the portion of the generic users s face to include only soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose and to exclude hard bony portions of the generic user's nose generally above the soft cartilaginous portions of the generic user's nose; and

an interior within the perimeter, the interior configured to overlay only the soft cartilaginous portions of the generic user's nose and portions of the generic user's face on either side of and below the soft cartilaginous portions of the generic user's nose;

the thin sheet of deformable thermoplastic polymer material including a depression sufficient to accommodate at least a portion of the generic user's nose surrounding the generic user's nostrils and being substantially flat on either side of and below the depression;

the thin sheet of deformable thermoplastic polymer material comprising holes, one for each of a particular user's nostrils, adapted to receive fittings for coupling the custom fitted mask to an external gas supply system, the thin sheet of deformable thermoplastic polymer material adapted to be:

heated to transition the mask blank from a non-deformable state into a deformable state;

applied against a portion of the particular user's face surrounding the particular user's nostrils while the mask blank is in the deformable state, such that the interior within the perimeter of the mask blank overlays only soft cartilaginous portions of the particular user's nose and portions of the particular user's face on either side of and below the soft cartilaginous portions of the particular user's nose and does not overlay hard bony portions of the particular user's nose generally above the soft cartilaginous portions of the particular user's nose; and

deformed against the portion of the particular user's face to cause the mask blank to conform substantially optimally to the particular user's unique facial features to form the custom fitted mask.