NASAL FILTER AND NASAL FILTER DEVICE

Abstract

A nasal filter comprising: - a support element (11, 11'), - a filter block (20), and - a fastening element (30); the support element (11, 11') being flexible, and the support element (11, 11') forming a cavity (110, 110') delimited by a plurality of longitudinal (111) and transverse (112, 113, 114) ribs; the filter block (20) comprising at least one filter layer (21, 22, 23, 24); and the fastening element (30) being configured to fasten the filter block (20) within the support element (11, 11').

Description

NASAL FILTER AND NASAL FILTER DEVICE TECHNICAL SECTOR This disclosure relates to a nasal filter and a nasal filter device designed to improve respiratory protection for workers in highly polluted industrial environments, such as steelmaking, mining, or the chemical industry. BACKGROUND In an industrial environment, such as a steelmaking environment, there is a high level of air pollution, particularly during the steel rolling process, which generates a considerable amount of suspended particles and harmful gases. This pollution, composed of particles, especially fine particles (PM2.5 and smaller), can penetrate the respiratory system and cause long-term damage if exposure is not controlled. Prolonged exposure to particulate matter poses a significant risk to respiratory health, promoting the development of lung diseases and chronic conditions. Face masks are well-known as a way to protect the respiratory system, and their use is recommended in these types of environments. However, the reality is that many factory workers avoid wearing them, despite the obvious need for protection. Among the most frequent reasons for not wearing a mask (despite being aware of the risks associated with not wearing one), users—operators or workers in industrial settings—mention the discomfort of wearing multiple pieces of personal protective equipment (PPE) simultaneously (such as helmets, goggles, and hearing protection), the feeling of constriction, and the negative association with the COVID-19 pandemic. These perceptions generate a widespread rejection of mask use, even at the cost of compromising long-term health. In other words, there is a need to protect workers in these types of environments from the inevitable exposure to contaminants with a filter device that is more readily accepted by workers and allows for continuous use, eliminating the psychological and physical barriers that conventional masks often generate. GENERAL DESCRIPTION The present disclosure solves the problems described above by means of a nasal filter and a nasal filter device as defined in the independent claims; possible embodiments of the nasal filter and the nasal filter device are defined in the dependent claims. A first aspect of the disclosure relates to a nasal filter, the nasal filter comprising: - a support element; - a filter block; and - a fastening element; the support element being flexible, and the support element forming a cavity delimited by a plurality of longitudinal and transverse ribs. This configuration of the support element with longitudinal and transverse ribs allows air circulation and forms a lightweight geometry that allows high structural strength with minimal weight, optimizing airflow through each support element. The filter block comprises at least one filter layer. The clamping element is configured to hold the filter block within the support element. Thanks to the configuration of the nasal filter, and its modularity, the filter block and the fastening element can be replaced independently, without the need for tools. The nasal filter is designed to be inserted into a human nostril and filter inhaled air in industrial environments. In certain embodiments the support element comprises at least one portion with a shape adapted to be inserted into a nostril; typically, into a human nostril. In certain embodiments, the support element comprises at least one essentially conical portion, typically an essentially truncated cone shape. This shape is adapted to the anatomical shape of a human nasal cavity. In certain embodiments, the support element also comprises an essentially cylindrical portion. This configuration, combining a conical and a cylindrical portion, has proven particularly suitable for adapting to certain nasal cavity anatomies. The support element can be made of a flexible material. This material can be a flexible polymer, such as a polyamide like PA12 or polypropylene (PP). This type of material gives the support element the necessary rigidity to withstand handling during filter block replacement, allowing the support element to be reused. Thanks to this flexibility, the nasal filter can adapt to the varying shapes of users' nostrils. For example, this flexible material can be a biocompatible elastomer, such as medical-grade silicone. In certain embodiments the support element is made of a material suitable for medical use. This filter layer, at least, can be tubular or similar in shape. This allows it to be easily mounted onto the mounting bracket. The at least one filter layer can be made of a flexible and / or elastic material. In certain embodiments, the filter block is smaller than the dimensions of the support element. Similarly, the clamping element may be smaller than the dimensions of the support element. This dimensional difference between the filter block and the clamping element relative to the structural element allows each filter block to be inserted into a specific cavity of the support element. In some embodiments, the supporting element comprises a plurality of articulating means, each articulating means between two or more of the plurality of longitudinal and transverse nerves. In this way, the nasal filter has flexibility through the articulation of the longitudinal and transverse nerves that form the nasal filter. The filter block may include a valve. This valve, typically one-way, is designed to prevent unfiltered air from entering, ensuring that airflow passes through the nasal filter. This valve allows unrestricted air to escape without passing through the filter layers, facilitating more comfortable breathing and reducing airflow resistance. The nasal filter as described is preferably an intranasal device, that is, it is inserted into the nostrils and acts directly on the airways. Another aspect of the disclosure relates to a nasal filter device comprising two nasal filters as defined in relation to the first aspect, or in any of the possible embodiments of the nasal filter defined above. In the nasal filter device, the support elements of each nasal filter can be joined together by a connecting element. This connecting element, which can be a bridge-type joint, can be detachable. In this way, the support structure can be manufactured not only as a monoblock—which can be simpler to produce using molding and injection molding—but also as a modular unit. This provides greater modularity, as only one of the two support elements can be replaced. Another aspect of the disclosure relates to a nasal filter device comprising: - a support structure; - two filtering blocks, and - a fastening element; The support structure comprises two support elements forming a cavity, each support element comprising longitudinal and transverse ribs; the support elements being joined together by a connecting element; such as a bridge-type element, typically curved or U-shaped. This connecting element may be made of flexible material. According to this aspect, each filter block comprises at least one filter layer, which may be tubular. Each clamping element is configured to hold each filter block within its respective support element. In other words, the nasal filter device's support structure has a skeletal-type shell-like structure, with a matrix of ribs forming an open mesh, which maximizes torsional rigidity and airflow efficiency, while maintaining a reduced mass. According to certain embodiments, the joining element between the support elements comprises a detachable joint. The nasal filter device is compatible with other respiratory protection methods and offers a viable alternative in cases where the use of other respiratory protection methods, such as masks, is impractical or rejected by users. Since breathing is primarily through the nose during rest and moderate exertion, the proposed nasal filter device intercepts airborne particles and potentially harmful gaseous compounds without creating the feeling of tightness characteristic of conventional masks. Furthermore, because the nasal filter device is modular, it is possible to adapt the nasal filter device to different environments and specific needs, with options geared towards industries with high concentrations of ferrous dust, toxic gases, or biological agents. The nasal filter device is designed so that the user can easily replace the filter block without tools, while the support element can be cleaned and reused several times, allowing for prolonged use over time. The different aspects and realizations of this disclosure defined above may be combined with each other, provided they are compatible. Other advantages and features of this disclosure will become apparent from the detailed description that follows and will be set out in the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS To complement the description being made and in order to help a better understanding of the characteristics of the disclosure, a set of drawings is included as an integral part of said description, in which, for illustrative and non-limiting purposes, the following has been represented: Figure 1.- Shows a perspective view of the nasal filter device according to one embodiment. Figure 2.- It is an exploded perspective view of the nasal filter device according to one embodiment. Figure 3.- Shows a perspective view of the support structure of the nasal filter device according to one embodiment. Figure 4.- Shows a front view of the support structure of the nasal filter device according to another embodiment. Figure 5.- Shows a perspective view of the multilayer filter of the nasal filter device according to one embodiment. Figure 6.- Shows a perspective view of the fastening element of the nasal filter device according to one embodiment. DESCRIPTION OF POSSIBLE IMPLEMENTATIONS The following description should not be considered exhaustive, but is given solely to outline the general principles of this disclosure. Examples of implementations of this disclosure are described below, with reference to the accompanying drawings. Figures 1 and 2 show an embodiment of a nasal filter device 100 (shown in Figures 1 and 2, assembled and exploded view, respectively) according to this disclosure, which has been designed as an innovative solution to improve workplace safety in industrial environments with high levels of particulate and vaporous contaminants. The nasal filter device 100 is an effective, ergonomic, and user-friendly alternative that addresses the current limitations of conventional personal protective equipment. The nasal filter device 100 comprises a support structure 10 (shown in Figures 3 and 4, respectively), a filter block 20, and a fastening element 30, all of which meet criteria for technical effectiveness, comfort, and user acceptance. The support structure is reusable, and the filters 20 are interchangeable, facilitating both hygiene and the sustainability of the proposed nasal filter. Figure 1 shows the assembled nasal filter device 100 in its operating position. Figure 2 shows an exploded view of the nasal filter device 100, displaying the different components from top to bottom according to their use. In this Figure 2, the filter block 20 is mounted on the clamping element 30, of which an upper rib 31 and a lower rib 32 are shown. In this way, they form a replaceable filter cartridge when saturation or usage protocols so indicate. Filter 20 is a tubular element made of a material with filtration technology. The materials used to manufacture both the support structure 10,10 and the filters 20 are selected based on criteria of biocompatibility, mechanical strength, and manufacturing feasibility, as well as, preferably, commercial availability. The filters 20 are made of a material that offers adequate efficiency without obstructing airflow or causing a feeling of blockage. The proposed 100 nasal filter device acts as an air filter, eliminating the discomfort associated with traditional face masks. This nasal filter device reduces exposure to contaminants in industrial environments and, at the same time, achieves greater acceptance among workers, thus ensuring its regular use. Figure 3 shows an embodiment of the support structure 10. This support structure 10 has two support elements 11 joined by a bridge 12 or connecting element, made of flexible material. Each support element 11 has an essentially truncated conical geometry with a cylindrical portion designed to adapt effectively and comfortably to the nasal anatomy. This geometry is formed by a series of longitudinal ribs 111 and transverse ribs 112, 113, 114 (ring-shaped), which leave gaps between them to allow unobstructed airflow and thus permit continuous breathing. On the inner part of the lower rib 112 of the support element 11 there is a groove 120, which may be a continuous perimeter groove or a plurality of grooves distributed along the inner perimeter of the support element. This groove (or plurality of grooves, which may also be in the form of a through hole) is intended to receive a tab 35 of the fastening element (see Figure 6). In one example, the lower nerve 112 is a ring, which may have a diameter of 14 mm or less. This value is slightly larger than the anthropometric average so that it can create an efficient seal through a slight natural dilation of the nasal entrance. The upper nerve 113 is a ring, which may have a diameter of approximately 10 mm, forming an essentially truncated cone shape to fit the nasal cavity. Between the lower nerve 112 and the upper nerve 113 in this example, there is an intermediate nerve 114, which is also ring-shaped. The portion of the support element 11 between the lower nerve 112 and the intermediate nerve 114 is essentially cylindrical. The total height of each support element 11 is approximately 20 mm. The thickness of the ribs is approximately 1 mm, seeking a balance between structural rigidity and flexibility to facilitate insertion. The proposed geometry and dimensions allow for a balance between respiratory comfort and filtering efficiency. In some embodiments, a sealing ring may be provided as a complement to the lower rib of the support element. Figure 4 shows a front view of another support structure 10 of the nasal filter device. This support structure 10 has two support elements 11 joined by a bridge 12 or connecting element, made of flexible material. In this example, each support element 11 has a truncated conical geometry, which also adapts effectively and comfortably to the nasal anatomy. This truncated conical geometry is formed by a series of longitudinal and transverse ribs (in the shape of a ring), which leave gaps between them for airflow. In this Figure 4, longitudinal ribs 34 are shown on the support element 11 on the right, and the clamping element 30 (shown in Figure 6) is shown. The dimensions of this support element 11 are similar to those of support element 11. In one example, the support structure 10, 10, including the support elements 11, 11 and the bridge 12, is made of a flexible material, such as a biocompatible elastomer or a polymer with some rigidity (PA12, PP), suitable for medical use, which gives it the necessary consistency to withstand handling during the replacement of the filter layers (ISO 10993-1, 2018). In one example, the material of the support structure 10, 10 is medical-grade silicone or TPE. The support elements 11, 11 and the bridge 12 can be manufactured as a single piece. Alternatively, the support structure 10, 10 can be modular, with the support elements 11, 11 being separate and connectable to each other, and / or connectable to the joining element or bridge 12. The filter block 20 uses materials capable of filtering fine particles without creating significant airflow resistance, aiming not only to comply with applicable regulations but also to ensure the most natural breathing experience possible for the user. For example, filters 20 may include electrostatic fiber, nanofibers, activated carbon, and antimicrobial components. For example, filter 20 is composed of a series of filter layers, each layer made with specific materials that perform distinct and complementary functions, maximizing efficiency without compromising breathing. Thanks to a multi-layered configuration, multiple levels of protection are achieved. The filter may consist of one or more of the following layers: an electrostatic fiber layer, a nanofilament layer, an activated carbon layer, and an antimicrobial layer. These layers may act sequentially or in combination, taking advantage of the intranasal anatomy to maximize contact with the airflow. A possible layer configuration of the filter 20 shown in Figure 5 is as follows: an electrostatic fiber layer 21 followed by a nanofilament layer 22, then an activated carbon layer 23, and on the opposite side from the electrostatic fiber layer 21, an antimicrobial layer 24. This sequential configuration allows for progressive and efficient filtration, in which each layer performs a specific function without overloading the following ones. The total thickness of the filter block can be from 1.8 mm to 2.2 mm; this thickness depends mainly on the compression to which the layers are subjected during assembly. Specifically, the electrostatic fiber layer 21 consists of fibers with diameters ranging from 15 µm to 40 µm. This layer retains larger particles (PM10) thanks to its electrostatic charge, which is relevant in environments with high levels of dust and aerosols. This layer 21 is characterized by its high initial filtration efficiency with low airflow resistance. This electrostatic fiber layer can be positioned as the outermost layer or as an intermediate layer, and it can maintain reasonable durability as long as it is not excessively exposed to humidity. The electrostatic charge on the electrostatic fiber layer can be optimized to increase the retention of ultrafine particles, which is relevant in steelmaking environments with metal oxide emissions. The nanofilament layer 22 can incorporate polymers such as polyacrylonitrile or polyethylene, and may have metallic coatings such as zinc or titanium oxides. For example, it may contain 1 µm to 5 µm nanofibers of polyamide or PVDF, with or without a metallic coating. This nanofilament layer 22 captures ultrafine particles (PM2.5 and PM0.3 and smaller, potentially toxic nanoparticles). In the nasal filter's position for use, this nanofilament layer 22 is positioned so that air, as it enters the nostril, passes through a mesh with very small diameters, thus improving the filtration level, even of nanoparticles. The durability of this nanofilament layer depends on the density of contaminants and the type of nanofiber used; under industrial conditions, the lifespan of this layer is longer if there is a prior electrostatic layer that retains most of the larger particles. The activated carbon layer 23 can be in a textile or granular form embedded in a non-woven backing and is made from thermally activated coconut or lignite carbon. This activated carbon layer 23 adsorbs vapors and gases thanks to its porous structure, which provides a high surface area for trapping volatile organic compounds, industrial vapors, gases such as CO, NOx, and SOx, and other chemical contaminants. This layer is particularly relevant in industries that handle solvents or produce gaseous emissions. The layer's durability depends on the type and concentration of the gases present. In the anatomical context and when using the nasal filter, this activated carbon layer 23 is positioned to allow adequate airflow without obstructing breathing. The antimicrobial layer 24 may be made from a base of synthetic fibers, such as polyester or polyamide, which may have been surface-treated or impregnated with active metal ions, primarily silver or copper, that act as antimicrobial agents. This combination allows for adequate mucosal compatibility while providing strength and stability during prolonged use. This is important with prolonged or repeated use of the nasal filter device, as it reduces the risk of microbial colony formation. This antimicrobial layer is typically hydrophobic and is placed inside the filter block 20, in its position of use, closest to the nasal mucosa. Its purpose is to inhibit the proliferation of bacteria, fungi, and other microorganisms within the device, thus maintaining the hygiene of the nasal filter. Due to its composition, this layer can remain active for a considerable period. However, its antimicrobial effects may be reduced by the accumulation of organic material or other external factors. Therefore, it is recommended to establish replacement intervals based on the frequency of use and actual working conditions. The filter can have additional layers to reinforce or complement the functionality of these four layers (electrostatic fiber, nanofilaments, activated carbon, and antimicrobial) in order to adapt to different contamination profiles. For example, a magnetic layer can be added, based on flexible polymers such as polyurethane or silicone impregnated with iron oxide, or on a flexible ferromagnetic mesh. This magnetic layer is especially useful in environments with high concentrations of fine ferrous dust, such as welding workshops or steel plants. Functions can also be combined within a single layer, for example, by integrating antimicrobial properties into a mesh of nanofilaments coated with copper or silver ions. This reduces the total number of layers and lowers respiratory resistance. The thickness of the activated carbon layer can also be increased, or variants impregnated with specific adsorbents can be used. This can be useful for work environments with a significant presence of acid gases (SOx, NOx) or higher concentrations of volatile organic compounds. The different layers proposed allow the 100 nasal filter device to be customized according to the type and level of contamination expected, facilitating a modular approach that extends the lifespan and improves filtration performance in each industrial scenario. Figure 6 shows an embodiment of the fastening element 30. This fastening element 30 has a geometry that can be frustoconical, cylindrical, or another similar geometry. In the example shown, the fastening element 30 has an upper rib 31 shaped like a ring, and a lower rib that in this example comprises two concentric rings 32, 33. The fastening element 30 comprises three longitudinal ribs 34, which leave gaps between them to allow airflow and at the same time provide stability to the fastening element. The fastening element also has four tabs 35 that allow the fastening element to be attached to the support element 11, 11 without the need for adhesives. In one example, the fastening element 30 has the following dimensions, which allows it to house the multi-layer filter 20 without compromising airflow: - External diameter of the lower nerve ring 32: approximately 12 mm, in accordance with the diameter of the lower nerve 112 of the support element and adapted to the average nasal anatomy. - Height: around 9-10 mm, also adapted to the dimensions of the support element. In one example of the nasal filter embodiment, the upper part of filter 20 comprises a flexible silicone membrane, composed of two semicircular sections, similar to half-moons or a hemisphere, which function as a one-way valve. These two halves are anchored at their centers, together forming a complete circumference. During exhalation, air pressure pushes both half-moons outward, allowing unrestricted airflow without passing through filter layers, thus facilitating more comfortable breathing and reducing airflow resistance. In contrast, during inhalation, the negative pressure generated inside the device causes the membrane to automatically close, ensuring that incoming air passes exclusively through the filter layers, thus guaranteeing efficient protection against particles and contaminants. This mechanism not only optimizes filter performance but also improves ergonomics and user experience by reducing moisture buildup and respiratory fatigue. For use, the nasal filter device's support structure 10 is inserted into the nose, ensuring the lower nerve 112 is flush with the nostril to guarantee correct positioning. The retaining element 30 and the filter block with the valve (if present) are inserted from below, ensuring a tight fit without any gaps through which unfiltered air could escape. If the filter has a valve, during inhalation, air passes through the different layers of the filter while the valve remains closed, ensuring complete filtration. During exhalation, the valve opens, releasing carbon dioxide and reducing accumulated moisture. When the filter layers reach their usage limit (either due to recommended usage hours or a noticeable increase in breathing resistance), the nasal filter device allows for the replacement of the filter block 20. This is done by removing the retaining element 30 along with the filter block 20 and replacing it with another retaining element 30 and filter block 20, simplifying maintenance and ensuring device hygiene. The support structure 10, typically made of silicone or TPE, can be washed with warm water and a mild cleaner, dried, and disinfected before its next use, extending the part's lifespan and optimizing replacement costs. In this way, the modular design of the nasal filter and the nasal filter device facilitates a quick and easy change, avoiding unnecessary disassembly and minimizing downtime during filter replacement. This nasal filter and nasal filter device (with two nasal filters) offers an innovative, intermediate alternative to existing protective devices: it provides effective protection against particles in industrial environments without obstructing the face or creating a feeling of pressure. Its intranasal design, interchangeable filters, and reusable structure overcome the main limitations of current solutions, offering a more balanced combination of effectiveness, comfort, and cost-effectiveness. In this text, the words "comprises", "includes" and their variants (such as "comprising", "including", etc.) should not be interpreted in an exclusive way, that is, they do not exclude the possibility that what is described includes other elements, steps, etc. Furthermore, this disclosure is not limited to the specific embodiments described but also includes, for example, variations that can be made by the average person skilled in the art (e.g., in terms of choice of materials, dimensions, components, configuration, etc.), within the scope of the claims.

Claims

1. A nasal filter comprising: - a support element (11, 11'), - a filter block (20), and - a fastening element (30); the support element (11, 11') being flexible, and the support element (11, 11') forming a cavity (110, 110') delimited by a plurality of longitudinal (111) and transverse (112, 113, 114) ribs; the filter block (20) comprising at least one filter layer (21, 22, 23, 24); and the fastening element (30) being configured to secure the filter block (20) within the support element (11, 11').

2. The nasal filter of claim 1, characterized in that the support element (11, 11') comprises at least a portion with a shape adapted to be inserted into a nostril.

3. The nasal filter of any one of claims 1-2, characterized in that the support element (11, 11') comprises at least one essentially conical portion. 4.The nasal filter of any one of claims 1-3, characterized in that the support element (11, 11') further comprises a portion having an essentially cylindrical shape.

5. The nasal filter of any one of claims 1-4, characterized in that the support element (11, 11') is made of a flexible material.

6. The nasal filter of any one of claims 1-5, characterized in that the support element comprises a plurality of articulation means, each articulation means being situated between two or more longitudinal and transverse ribs of the plurality of longitudinal and transverse ribs.

7. The nasal filter of any one of claims 1-6, characterized in that the filter block (20) comprises a plurality of filter layers (21, 22, 23, 24). 8.The nasal filter of any one of claims 1-7, characterized in that the at least one filter layer (21, 22, 23, 24) comprises electrostatic fiber, nanofibers, activated carbon, and / or antimicrobial components.

9. The nasal filter of any one of claims 1-8, characterized in that the at least one filter layer (21, 22, 23, 24) is made of a flexible and / or elastic material.

10. The nasal filter of any one of claims 1-9, characterized in that the filter block (20) and / or the fastening element (30) has dimensions smaller than the dimensions of the support element (10, 10').

11. The nasal filter of any one of claims 1-10, characterized in that the filter block (20) comprises a valve.

12. The nasal filter of any one of claims 1-11, characterized in that the device is intranasal. 13.The nasal filter of any one of claims 1-12, characterized in that the nasal filter is configured to be inserted into a human nostril and filter inhaled air in industrial environments.

14. The nasal filter of any one of claims 1-13, characterized in that the nasal filter is modular.

15. The nasal filter of any one of claims 1-14, characterized in that the filter block (20) and the fastening element (30) are independently replaceable without the need for tools.

16. A nasal filter device (100) comprising two nasal filters according to any one of claims 1-15.

17. The nasal filter device (100) of claim 16, characterized in that the support elements (11, 11') of each nasal filter are joined together by a connecting element (12). 18.The nasal filter device (100) of any one of claims 16-17, characterized in that the connecting element comprises a detachable joint.

19. The nasal filter device (100) of any one of claims 16-18, characterized in that the device is modular.

20. A nasal filter device (100) comprising: - a support structure (10); - two filter blocks (20); and - two fastening elements (30); the support structure (10) comprising two hollow support elements (11, 11'), each support element (11, 11') comprising longitudinal and transverse ribs; the support elements (11, 11) being joined together by a connecting element (12); and each filter block (20) comprising at least one filter layer. and each clamping element (30) being configured to clamp each filter block (20) within each support element (11, 11').