Patent Grant
7469699
1. Field of the Invention
The present invention relates to a thin profile air purifying filter blower having a thin replaceable filter cartridge that provides enhanced portability and wearability, with the capability to easily replace the filter cartridge even during location of the unit in hot zones.
2. Description of Related Art
Respiratory devices, such as protection masks, also interchangeably referred to herein as face masks or masks, are well known. Civilians, law enforcement, military personnel, fire fighters and other groups of individuals (often referred to as “responders”), as well as others (herein collectively referred to as “users”), wear masks for protection in environments containing harmful, and even hazardous, airborne toxins, and other hazardous or noxious materials. Such toxins and other materials can be hazardous upon exposure to respiratory systems and generally take the form of harmful gases, vapors, aerosols, or particulates. The respiratory hazards may result from various agents, such as nuclear, biological and chemical (NBC) agents.
One type of breathing apparatus, known as a Powered Air Purifying Respirator (PAPR) (also referred to interchangeably herein as “PAPR protection system”), provides for fan-forced positive pressure breathing. PAPR protection systems are typically used in environments in which ambient air is relatively oxygen-rich and where filtering elements are effective in removing contaminants before the air is inhaled by the user. PAPR protection systems typically include a face mask, a filtering element that removes contaminants from the air, a blowing element (interchangeably referred to herein as a “blower”), such as a fan, and a power source that provides operational power to the blowing system. In operation, the fan or other blowing element continuously supplies filtered air to the face mask, where the filtered air replenishes the internal space of the mask. Exhaled air (also interchangeably referred to herein as “spent air”), in turn, is continuously expelled.
Conventional PAPR protection systems have numerous drawbacks. For example, most existing PAPR protection systems do not allow simple and efficient exchange of spent filters for new filters, especially in contaminated environments. One typical hindrance to efficient exchange of filters in conventional PAPR protection systems is the use of threaded connector parts for connecting the replaceable filters. When swapping filters in these conventional PAPR systems, the user must unscrew the old, spent filter from the filter port, discard the used filter, quickly position a new, unspent filter into the filter port to limit exposure to ambient air through the unfiltered filter port, and then thread the new filter into the port. Accordingly, the process of exchanging filters in these systems is both time-consuming and can lead to increased risk of exposure of the user to contaminants, especially if the filter port is even briefly opened or otherwise unprotected.
Due to these drawbacks, PAPR protection systems are limited in their applicability and range of use. For example, the potential exposure to contaminants in ambient air during filter exchange results in conventional PAPR protection systems typically allowing swapping of filters only in safe zones (interchangeably referred to herein as “clean zones”)—those areas where the ambient environment does not contain toxic, harmful, or otherwise to be avoided contaminants. In addition, a conventional PAPR system user may require some level of decontamination prior to replacing the filter within the clean zone.
Another drawback of conventional PAPR protection systems is that the filters themselves are typically bulky and cumbersome. Conventional PAPR protection systems generally have relatively large, projecting cylindrically shaped filter cartridges. For example, when the main body of such a system is worn on a user's back, as occurs in typical use, the cartridges project from the user's body. This configuration results in the systems being bulky and cumbersome, severely hindering user freedom of movement, and often rendering conventional PAPR system use impractical in some environments. For example, a user carrying the bulk of a conventional PAPR system on the back must account for the relatively large size PAPR when entering cramped spaces. As a result, conventional PAPR protection systems have limited usefulness in such limited space environments as vehicles, airplanes, and buildings, and their use may adversely impact maneuverability when used in such applications as combat situations. The user must also account for the added bulk of PAPR systems when performing such actions as rolling, crouching, or ducking.
Yet another drawback of wearing the bulk of a conventional PAPR protection system on the back is the difficulty that this location presents to the user when filter replacement is necessary. Rather than allowing users to carry out such replacement by themselves, the aid of a second person is often required. The inability of users to exchange filters by themselves can thereby increase the risk to the user and decrease range of operation, since these users must rely on a second person typically remote from the working environment when the sometimes urgent need for filter replacement occurs.
Alternatively to wearing the main body of a conventional PAPR system on the back, the bulk of these systems may be attached at the user's waist. While such usage reduces some problems associated with wearing on the back, such as difficulty with unaided replacement of filter cartridges, other problems remain with this approach. For example, whether the main body of the system is located on the back or at the waist, a lengthy connection hose typically must extend from the main body of the system to the air inlet of the face mask. As a result of the need for a lengthy breathing hose, conventional PAPR systems generally have increased airflow loss and greater breathing resistance than systems having short hoses. Moreover, the long breathing air hose has a greater tendency to become kinked, damaged, or entangled during use, potentially both restricting movement of the user and increasing the danger of loss or contamination of air supply.
Accordingly, there remains an unmet need in the art for a PAPR protection system that allows users a wider range of operation and increased ease of use. There is a corresponding similar need for a PAPR system that allows users less limited range of motion and access to areas of limited space. In particular, there is an unmet need for a PAPR protection system that is less cumbersome and bulky than conventional PAPR protection systems, yet maintains the volumetric flow rate of filtered air of conventional PAPR filters. Furthermore, there is an unmet need in the art for a PAPR protection system that allows users to quickly and safely swap filter cartridges (also interchangeably referred to herein as “filters”) in an efficient manner, without subjecting the user to possible dangers that may be present in the ambient environment, while also allowing various components, including the filter cartridges, to be stored and transported effectively and efficiently.
In order to overcome these needs, as well as others, the present invention provides a thin profile PAPR blower system and method of use that operates in conjunction with a replaceable thin profile filter cartridge. Features of the present invention allow a user to swap spent filter cartridges for new filter cartridges, without assistance and without compromising the safety of the user, even when the user is located in a hot zone.
The resulting system of the present invention is more compact, maneuverable, portable, and safer than PAPR protection systems of the prior art. The present invention can be conveniently worn against the user's side, back or front, in a manner so as to allow the user to perform a wide range of maneuvers, such as rolling or lying on the stomach, that are not easily performed when wearing conventional PAPR systems. The thin profile design of the present invention also allows the blower units and filters to be easily and efficiently stacked or otherwise packed, thereby allowing more efficient transport or portability than the conventional blowers and filters. Moreover, the unique configuration of the thin profile filter provides an increase of approximately 25% relative to conventional filters with respect to the volume of filtered air.
Various other components of the present invention include a control mechanism, such as an on/off switch or other blower modulator, a minimal length hose or other conduit for delivering filtered air to the face mask, a power supply contained within the PAPR system housing, specialized attachment mechanisms for securing the bulk of the system to the user's body, features for sealably connecting and replacing filter cartridges, and a quick change locking mechanism to secure the filter cartridges when installed to the system. In some embodiments, a remotely located control device is also provided, facilitating, for example, control of blower functions in situations limiting access to housing located controls.
The thin profile design of the filter component of the present invention includes the compact use of one or more filter elements arranged so as to effectively filter contaminants or other materials contained in intake air. The filtering elements can be of any of various types known in the art, so long as intake air is able to enter and pass through the filtering elements, where toxins or other materials are removed and trapped, with only filtered air passing through. The filter component of embodiments of the present invention also includes a slidable and removable cover, which is ejected when the filter is installed.
In another aspect of the present invention, the blower and/or filter cartridges include features to secure the bulk of the system to the user's body. In particular, either or both of the filter and blower may include attachment mechanisms connectable to harnesses or other mounting devices worn by the user, so as to secure the system against the user's body (e.g., chest, back, or sides) without significantly restricting the user's motion.
In one embodiment of the present invention, the filter is attached to an attachment location at the lower end of the blower unit. When a filter becomes spent, a new filter may be slidably installed to replace the spent filter, and the spent filter simultaneously ejected, without the blower losing sealed engagement with at least one of the filters at all times. In one embodiment, grooves are provided on each filter that are configured so as to allow mating engagement with corresponding guides located at an attachment location on the lower surface of the blower. As the new filter is slidably engaged into position on the blower, the filter to be replaced slides out of position and is ejected from the PAPR protection system. Seals located on one or both of the grooves and guides ensure that during the exchange of filters and during operation, contaminants from the ambient environment are unable to enter the PAPR protection system.
In operation, air is drawn into the filter by the blower, passes through the filter to the blower, and is driven from the blower to the face mask, where the user inhales the filtered air. Air is driven to the face mask via a filter outlet angled relative to the blower body and an air hose or other conduit that smoothly connects the blower and the face mask. As a result of the angling of the filter and location of the bulk of the system on the user's chest when so worn, a shorter air hose or other conduit is required than for conventional protection systems, thereby reducing the likelihood of kinking or other damage occurring during use. When worn on the front side of the user's body, the system's operations may also be easily monitored by the user.
Additional aspects, advantages, and novel features of the present invention will become more apparent from the following description, with reference to the accompanying drawings.
In the drawings:
The present invention provides a thin profile PAPR filter blower system and method of use that operates in conjunction with a thin profile filter cartridge. Among other advantages, the present invention allows an unaided user to swap filter cartridges without compromising the safety of the user, even when the user remains located in a contaminated environment during filter exchange. Other components of the system include a blower control mechanism, a short hose or other conduit for delivering filtered air to a worn face mask, a self-contained power supply, optional attachment features to secure the system to a wearer's body, features for sealably connecting and replacing filter cartridges, and a quick change locking mechanism to secure and release filter cartridges. An optional remotely located control device is also provided.
Among other things, the present invention overcomes problems of the prior art by providing a thin profile PAPR protection system that facilitates swapping of thin profile filter cartridges. In one embodiment, both the filter and the blower unit have a rectangular cross-sectional shape. The rectangular shape allows for efficient stackability, which in turn allows for easier transport and storage of the units. The cross-sectional shape of the filter and blower may also be many other shapes, such as triangular, elliptical, or circular, that likewise allow the filter to maintain a thickness and shape supporting efficient stacking and transportation, as well as enhanced ease of use.
The thin profile shape of the filter of the present invention is generally more compact than the cylindrical shape of conventional filters, having a thickness much less than the standard diameter of 106 millimeters for existing filters. As a result, the blower and corresponding filter of the present invention have an overall size that is approximately one-third the size of a conventional filter and blower while providing an increase of approximately 25% in terms of the volume of filtered air. Although a reduction in size has always been desired in the art, the ability to reduce size while maintaining operability has not been previously accomplished in conventional filters and blowers.
While decreasing the overall size of the filter, the present invention nevertheless increases the volume of filtered air and capacity by approximately 20-25%, compared to conventional filters. As a result, the filters of the present invention have a longer use life, as compared to the use life of typical conventional filters.
The above-identified and other features of the present invention also offer numerous additional advantages over conventional PAPR blowers. For example, the filter/blower unit of the present invention is less bulky and cumbersome than conventional filters and blowers, among other things allowing greater maneuverability for a user wearing the system. In one embodiment, the filter/blower unit is about two inches thick. In another embodiment the filter/blower unit is no more than four inches thick, preferably about three inches thick. As a result, users of the present invention are able to fit into tighter spaces than users of conventional PAPRs. Additionally, the present invention allows the user to operate with a wide range of motion and to perform actions that are otherwise difficult with conventional PAPR blowers. For example, the thin profile design of the present invention permits users to perform such actions as laying down, rolling, and crouching, which are difficult, if not impossible, with conventional filters and blowers.
Another benefit of the present invention is increased safety for the user. The present invention allows users to replace their own spent filters, even in hot zones, without compromising safety. The ability to swap the filter in a hot zone is generally known as “hot swappable.” This function increases user safety because, for example, once a filter is spent, it can be readily replaced, and the user can continue to receive filtered air. In such operations, the present invention allows users to attach a replacement filter to the blower unit quickly, efficiently, and safely. As a result, users do not need to be concerned with the risk of potential exposure to toxins or contaminants. Due to the ability of the user to self-replace the filter, the user need not depend on assistance when a filter becomes spent.
Further, the air hose of other conduit of the present invention does not have to be as long as those of conventional blowers. The thin profile design of the present invention, combined with the angled air outlet, allows the air hose or other conduit to flowably connect to the mask with reduced risk of kinking, entanglement, or rupturing of the hose.
Yet another related benefit of the present invention over the prior art is increased applicability of PAPR protection systems. The filter/blower unit of the present invention allows such users as military personnel and first responders to enter areas previously inaccessible with conventional PAPR protection systems. Moreover, with the ability to swap filter cartridges without sacrificing safety, users have the capability to penetrate deeper into hot zones, swapping old filters for new filters along the way as filters become spent.
Embodiments of the present invention will now be discussed in greater detail with regard to
As shown in
Collectively, the filter 8 and blower unit 10 comprise the bulk of the main body (non-face mask portion) 1000 of the system of the present invention. The main body 1000 can be manufactured from numerous suitable materials, such as plastic or other material that is relatively lightweight and durable. In one embodiment, components of the main body 1000 are constructed from carbon-reinforced plastic and/or covered by Kevlar®, made by DuPont of Wilmington, Del., or other bulletproof or impact-resistant material. Bulletproofing the main body 1000 provides an additional protection feature for users, particularly when the main body 1000 is worn on the user's chest, back or sides while the user is in combat or in other situations presenting impact hazards.
The filter 8 includes grooves 12 on one end that slidably engage corresponding guides 11 on one end of the blower unit 10. Thus, the grooves 12 on the filter 8 and the corresponding guides 11 on the blower unit 10 slidingly mate with each other to allow the filter 8 to be slidably attached to the blower unit 10.
As shown in
The left face 8l of the filter 8 being replaced, which is distal from the force F exerted on the replacement filter 8′, in turn also moves left, relative to left face 10l of the blower unit 10, as shown in
Simultaneously with the travel and ejection of the filter 8 being replaced, the replacement filter 8′ travels along the guides 11 until the left face 8l′ and right face 18r′ of the filter 8′ generally align with the edges 10l and 10r, respectively, of the blower unit 10. The new filter 8 is then operationally engaged with the blower unit 10, and the air aperture of the replacement filter 8′ (corresponding to air aperture 31 of the filter 8 being replaced) allows filtered air to flow from the replacement filter 8′ to the interior of the blower unit 10.
In one embodiment, the replacement filter 8′ includes a filter cover 55, which is disposed on the top end of new filter 8′ prior to being attached to the blower unit 10. The filter cover 55 matingly attaches via the grooves of the replacement filter 8′ (corresponding to the grooves 12 of the filter 8 being replaced) and protects the replacement filter 8 from contamination (e.g., ensures sterility of the replacement filter 8′) prior to installation on the blower unit 10. In one embodiment, the filter cover 55 has the same cross-sectional shape as the guides 11 on the blower, allowing the filter cover 55 to engage matingly with the grooves on the filter 8′ and to slide along these grooves during engagement of the replacement filter 8′ with the blower unit 10.
As the replacement filter 8′ travels into full engagement with the blower unit 10 along the grooves of the filter 8′ via the guides 11 of the blower unit 10, the removable filter cover 55 is pushed (stripped) from the replacement filter 8′. When the filter 8′ and blower unit 10 fully engage each other, the filtered air outlet of the replacement filter 8′ communicates with a filtered air chamber of the blower unit 10, as, for example, described further below in conjunction with
In one embodiment, the replacement filter 8′ is further secured to the blower unit 10 (i.e., prevented from slidable movement) via a locking member, such as a filter safety lock 2, which is shown in a locked position in
In one variation, as shown in
In the variation shown in
In operation, to engage the lock 2, as the filter 8 travels into place when being engaged with the blower unit 10, the engaging member 2b slidably passes over the curved surface of the first encountered one of the protruding extensions 2c and comes to rest in the groove 2g upon full engagement. Due, for example, to the biasing of the engaging member 2b against the face 10f of the blower 10, the engaging member 2b is biasedly retained in the groove 2g, and as a result, does not easily slide over the protruding extensions 2c after engagement. In one variation, once in the locked position, the filter may only easily be removed following manual retraction (e.g., lifting) of the engagement member 2b to allow travel past the extensions 2c.
In the embodiment illustrated in
As further shown in the cutaway illustration of an exemplary blower unit 10 presented in
In one variation of the present invention, as shown in
Additionally, in one variation of the present invention, the blower unit 10 includes an external control connector 5, to which a remote control cable may be connected. The external control connector 5 is useful, for example, when the user wears the main body 1000 on the user's back, and the switch 3 on the blower unit 10 cannot be easily reached by the wearing user. In this situation, a remote switch may be connected to the blower 10 via the connector 5, and located, for example, on the user's chest, mask, or other easily reachable area. In one variation, the remote switch can be attached to the user via a clip. In some variations of the present invention, no switch 3 is present and the blower operates via pressure responsiveness (e.g., automatic operation based on breathing pressure of the wearing user), as is generally known in the art.
In an embodiment of the present invention, the blower includes a replaceable power source, such as batteries, to provide power to allow movement of the filtered air to the user. Any battery that provides sufficient power to the blower can be used. For example, in one embodiment, one or more rechargeable “D” size batteries provide power to the blower. In the variation shown in
In one variation, each battery housing area includes one or more battery covers 7a to facilitate replacement of the batteries within the blower unit 10. Operational and electrical connection of the batteries to the blower, via control device 112, and the switch 3, for example, may be made via wires, printed circuits, and/or other circuit components generally known in the art.
As further shown in the embodiment of
The angled disposition of the air outlet 4 thereby allows the connected hose or other conduit to have a minimized length in extending to a connected protection mask worn by the user. Furthermore, the angled disposition of the air outlet 4 allows for a smooth bend in the air hose leading to the user since, generally, the shorter the air hose, the greater the need for an air outlet 4 that creates a smooth bend in the air hose. The direction that the air outlet 4 extends relative to the blower unit 10 (e.g., to the right or left side of the blower unit 10, as shown in
In order to enhance user wearability, embodiments of the blower unit 10 and/or filter 8 of the present invention include securing devices to secure the main body 1000 to the user. In the variation shown in
As further illustrated in
Various other aspects of the filter 8 of the present invention will now be described in further detail in conjunction with
Generally, the filter 8 can perform its function of filtering ambient air in any number of ways, as known in the art, and any filtering mechanism that can effectively remove harmful or noxious contaminants and/or toxins from filtered air prior to inhalation by the user can be used with the present invention. For example, any present or future developed filter approved by the National Institute of Safety and Occupational Health (NIOSH) may typically be incorporated in the filter of the present invention.
As particularly shown in
As shown in
As further illustrated in
Generally, the main body 1000 of the present invention may be worn against the user's stomach and/or chest, as illustrated in
In the embodiment shown in
Also shown in
While there has been described what are at present considered to be preferred embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention. Other modifications will be apparent to those skilled in the art.
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