Powered Air Purifying Respirator with Face Shield

Abstract

1. An air-purifying respirator for a user, the air-purifying respirator comprising: a face shield configured to shield the user's face from droplets; a head strap configured to encircle at least a portion of the user's head, the head strap configured to support the face shield; at least one fan; a fan housing positioned proximate an upper edge of the face shield, the fan housing configured to support the fan; a filter media positioned on an outer peripheral flange of the fan housing, maximizing a surface area of ​​the filter media; and a face shroud connected to a periphery of the face shield, the face shroud configured to provide a seal between the face shield and the user's face, thereby facilitating drawing air through the filter media;

Description

[Technical Field]

[0001] The present disclosure is directed to air filters and face masks. More specifically, the present disclosure is directed to face shields with powered air-purifying respirators. [Background technology]

[0002] The air we breathe contains dust, dirt, pollen, harmful gases, bacteria, viruses, mold, and other airborne particles. During the COVID-19 era, various approaches and forms have been used to prevent the spread of the virus from person to person, such as wearing filter materials and / or face shields over people's noses and mouths, social distancing in public places, and sheltering in place. However, some workers in categories classified as essential are still required to perform their job duties, and some are unable to perform such duties and maintain social distancing.

[0003] One approach to preventing the spread of influenza viruses has been the use of N95 respirators, surgical masks, and other face masks that attempt to create a physical barrier between the wearer's mouth or nose and potential contaminants in the surrounding environment. N95 respirators are regulated as Class II medical devices under product code MSH and are exempt from 510(k) premarket notification unless the respirator is labeled or otherwise claims to filter, reduce, and / or kill a specific amount of viruses or bacteria. Therefore, without a label claiming to filter a specific amount of viruses or bacteria, these respirators can stop large particle droplets, spatter, spray, or splashes that may contain pathogens (viruses and bacteria) from entering the wearer's nose or mouth. One disadvantage of this approach is the difficulty of achieving a seal around the respirator and the user's face. Another disadvantage of this approach is that these respirators do not filter or block very small airborne particles that may contain pathogens (viruses and bacteria) from entering the wearer's nose or mouth. Additionally, another disadvantage or drawback of these approaches is that these respirators are made of different thicknesses, which can also affect how easily a person can breathe through the material.

[0004] One approach to preventing the spread of influenza viruses has been to use face shields, which create a physical barrier between the eyes, mouth, and nose, and attempt to block large particle droplets, splashes, sprays, or droplets that may contain pathogens (viruses and bacteria) from entering the wearer's eyes, nose, or mouth. One disadvantage or drawback of these approaches is that these face shields have difficulty protecting against splashes, sprays, or droplets on the sides or back.

[0005] It should therefore be apparent that there exists a perceptibly unmet need for a powered air-purifying respirator face shield and method of use that can be configured to address at least some aspects of the above commonly discussed problems for preventing the spread of viruses and other contaminating particulates via a dual-stage protective device for blocking small and large particle droplets, spatters, sprays, or splashes, which may contain pathogens (viruses and bacteria), from entering the wearer's eyes, nose, or mouth. Summary of the Invention [Means for solving the problem]

[0006] Briefly, in exemplary embodiments, the present disclosure may overcome the above-mentioned disadvantages and may fill a recognized need for a powered air-purifying respirator-face shield and method of use, including a powered air-purifying respirator for a user's head having a face, forehead, and back of the head, the powered air-purifying respirator comprising: a face shield configured to shield the user's face; a face shroud connected to a periphery of the face shield, the face shroud configured to provide a seal between the face shield and the user's face; a head strap configured to encircle at least a portion of the user's head, the head strap configured to support the face shield; at least one fan; a fan housing disposed proximate an upper edge of the face shield, the fan housing configured to support the fan; and a filter chamber connected to the fan housing, the filter chamber configured to support a filter media disposed proximate an external environment.

[0007] Thus, in one aspect, the present disclosure can be configured to provide filtered air to a wearer via a battery-powered electric fan and filter system, the system consisting of a transparent face shield, air filter media, a filter media housing, an electric fan, a head strap, and a battery.

[0008] Thus, in another aspect, the present disclosure can be configured such that air is drawn through filter media located above the outer eyebrow region of the face shield via a powered fan mounted between the filter media and above the plane of the wearer's eyebrows.

[0009] Thus, in another aspect, the present disclosure can be configured to include a filter media and fan that can draw air through the filter media, which can filter smoke or fumes, filter small particles, filter specific amounts of viruses or bacteria, reduce the amount and / or kill viruses, bacteria, or fungi, or affect (purify) the allergenicity. Additionally, the filter media can include coating technology to reduce and / or kill microorganisms.

[0010] Thus, in another aspect, the present disclosure may be configured such that filtered air is blown into the space between the wearer's face and the interior of the face shield, thereby creating a positive pressure condition that protects the wearer from exposure to potentially contaminated ambient conditions.

[0011] Thus, in another aspect, the present disclosure can be configured with a face shroud connected to the periphery of the face shield, the face shroud forming a seal around the periphery of the respiratory tract and the face of the user, providing a seal between the face shield and the user's face to block small and large particle droplets, spatter, spray, or splashes, which may contain pathogens (viruses and bacteria), from entering the wearer's eyes, nose, or mouth.

[0012] Thus, in another aspect, the present disclosure can be configured such that the barrier allows air to vent through the shroud, but can also serve to filter potential pathogens before the wearer's exhaled breath and, therefore, exhausts into the environment. In applications that do not require filtration of inhaled air, the shroud can also protect the wearer from flying dust and debris that could potentially overwhelm the positive pressure envelope, and provide side and back splash, spray, or splash protection.

[0013] Thus, in another aspect, the present disclosure may be intended to encompass any and all dimensional relationships, including variations in size, material, shape, form, location, function, and method of operation, assembly, and use.

[0014] In another exemplary embodiment, there is provided an air-purifying respirator for a user's head having a face and forehead to deliver filtered air and provide a shield against droplets, the respirator comprising a face shield configured to shield the user's face from the droplets; and a powered air-purifying system, the system comprising: at least one fan providing positive air pressure between the face shield and the user's face; and a fan housing positioned proximate an upper edge of the face shield, the fan housing having a fan support, a forehead support wall, and an outer peripheral flange to support the fan therein and enable efficient movement of the air. a head strap attached to the fan housing, the head strap configured to encircle at least a portion of the user's head and the head strap configured to support the fan housing; and a filter media disposed on the outer peripheral flange of the fan housing, the filter media maximizing a surface area of ​​the filter media, wherein the fan draws air through the filter media and the fan forces filtered air out of the fan housing between the face shield and the user's face as the positive air pressure.

[0015] In another exemplary embodiment, an air-purifying respirator for a user's head having a face and forehead to deliver filtered air and provide a shield against droplets, the respirator comprising: a hard hat having a visor; and a powered air-purifying system disposed proximate to the visor, the system being a face shield configured to shield the user's face from the droplets; the face shield; at least one fan providing positive air pressure between the face shield and the user's face; a fan housing disposed proximate to an upper edge of the face shield, the fan housing having a fan support, a forehead support wall, and an outer peripheral flange, the fan housing configured to support the fan therein and enable efficient movement of the air; and a filter media disposed on the outer peripheral flange of the fan housing, the filter media maximizing a surface area of ​​the filter media, the fan drawing air through the filter media and pushing filtered air out of the fan housing and into the user between the face shield and the user's face.

[0016] Features of the present disclosure may include a face mask with a built-in removable external air filter and a powered air blower that removes contaminants from the ambient air and continuously delivers purified air under positive pressure to the area between the wearer's face and the transparent or see-through face shield.

[0017] A feature of the present disclosure can include a fan for drawing air through an external filter, allowing for the use of smaller porosity and pore connectivity filter materials with nano- and micro-fiber layers. This contrasts with the wearer's lung capacity when breathing air into filter materials with pores between 10 and 65 micrometers, such as N95 masks. Masks, surgical masks, and N95 masks have average pore sizes of 47, 33, and 30 micrometers, respectively. Effective filter materials must be able to process micro-scale droplets that evaporate into nano-scale aerosols carrying pathogens (viruses and bacteria). Fan-powered air-purifying respirators (PAPRs) generally provide wearers with a higher level of protection from airborne pathogens, substances, and smoke than less powerful filtering masks.

[0018] Features of the present disclosure include the possibility of including an external or outer filter relative to the fan and mask body (rather than an internal filter that contaminates the internal passages before the filter) for ease of replacement, and an increased filter surface area to provide sufficient airflow through the filter material to provide positive air pressure in close proximity to the wearer's eyes, nose, and mouth.

[0019] Features of the present disclosure may include providing a portable, self-contained, powered air-purifying respirator and face shield that provides filtered air to the wearer's facial area, excludes unpurified air, and protects the wearer's eyes, nose, and mouth.

[0020] A feature of the present disclosure may include a face shroud connected to the periphery of the face shield, the face shroud configured to provide a seal between the face shield and the user's face to block droplets expelled into the environment by coughing or sneezing.

[0021] Features of the present disclosure may include greater comfort for the wearer than less powerful respirators. Additionally, PAPRs allow the wearer's mouth to be seen by others, such as coworkers or patients, which can aid communication and reduce miscommunication, especially during critical decision-making situations.

[0022] Features of the present disclosure include rapid change or replacement of the filter media because the filter material is on the exterior of the mask housing; a variety of filter materials with nano- and micro-fiber layers can be utilized; and the filter material can be rotated frequently to ensure a constantly dry, bacteria-, virus-, and particle-free filter material.

[0023] Features of the present disclosure may include optimizing the placement of the powered fan and filter assembly directly in front of the wearer's forehead, eliminating the need for complex ducts and associated headgear.

[0024] Features of the present disclosure may include a filter media and powered fan assembly that minimizes the number of parts, reducing both the weight and bulk of this new PAPR.

[0025] Features of the present disclosure may include a filter media configured as a two-dimensional planar shape that can be fitted to the outside of a filter cowl and peripheral flange, providing a large surface area of ​​filter media for filtration while not requiring any complex manufacturing forming operations compared to other more complex filters, such as pleated media fitted into cartridges. This filter design therefore alleviates supply constraint issues, especially during high demand cycles during pandemics, reduces the overall cost of filter material, and allows maximum flexibility for utilizing alternative filter media in emergency situations.

[0026] A feature of the present disclosure may include a filter media configured with a removable adhesive backer for adhering and sealing the filter media to the exterior of the filter cowl and peripheral flange.

[0027] A feature of the present disclosure may include mounting the system on a helmet, such as a construction hard hat, welding helmet, or the like.

[0028] A feature of the present disclosure includes that the respirator system may be utilized in other industries or integrated with other face shields to provide air movement functionality thereto.

[0029] Features of the present disclosure may include use with or without a breathable, resilient face shroud that forms a bridging barrier between the wearer's face and the face shield.

[0030] Features of the present disclosure may include being lighter and more economically manufactured than the current state of the art PAPRs.

[0031] Features of the present disclosure may include not requiring a conduit to move air from the fan to the wearer's face.

[0032] Features of the present disclosure may include efficiently designing the fan support, forehead support wall, and outer perimeter flange to provide a fan plenum box for the electric fan that allows for efficient movement of air and provides a large surface radius for the filter media.

[0033] These and other features of the face shield with powered air-purifying respirator and method of use will become more apparent to those skilled in the art from the preceding summary and the following brief description of the drawings, detailed description of illustrative embodiments thereof, and claims, when read in light of the accompanying drawings or figures.

[0034] The powered air-purifying respirator face shield and method of use of the present invention will be better understood by reading the detailed description of the preferred and selected alternative embodiments in conjunction with the accompanying drawing figures, in which like reference numerals indicate like structure and refer to like elements throughout, and which are described as follows: [Brief explanation of the drawings]

[0035] [Figure 1] FIG. 1 is a perspective side view of a face shield with a powered air-purifying respirator system according to selected embodiments of the present disclosure; [Figure 2] FIG. 2 is a perspective side view of a face shield with a powered air-purifying respirator system according to selected embodiments of the present disclosure, shown in use and worn by a wearer or user; [Figure 3] FIG. 3 is a partial cross-sectional side view of a face shield with a powered air-purifying respirator system according to selected embodiments of the present disclosure, showing the airflow pattern through the filter material, the fan, and into the area between the face shield and the wearer's face; [Figure 4] FIG. 4 is a top perspective view of a face shield equipped with a powered air-purifying respirator system according to selected embodiments of the present disclosure, showing the outer filter material removed to expose the inner fan chamber and fan assembly; [Figure 5] FIG. 5 is an exploded perspective view of a face shield with a powered air-purifying respirator system according to selected embodiments of the present disclosure; [Figure 6] FIG. 6 is a bottom perspective view of a face shield of a powered air-purifying respirator system according to selected embodiments of the present disclosure, showing the face shield, fan housing, and visor; [Figure 7] FIG. 7 is a perspective side view of a powered air-purifying respirator system according to selected embodiments of the present disclosure shown in use and worn by a wearer or user with the addition of a filter media breathable cover; [Figure 8] FIG. 8 is a partial cross-sectional side view of a powered air-purifying respirator system according to selected embodiments of the present disclosure, illustrating the airflow pattern through the breathable cover, filter material, fan, and into the area between the face shield and the wearer's face; [Figure 9] FIG. 9 is an exploded perspective view of a face shield, main structure, fan assembly, and headgear of a powered air-purifying respirator system according to selected embodiments of the present disclosure; [Figure 10] FIG. 10 is a bottom perspective view of the face shield, main structure, fan assembly, and headgear of a powered air-purifying respirator system according to selected embodiments of the present disclosure, showing the fan diffuser frame and fan diffuser; [Figure 11] FIG. 11 is an exploded perspective view of the powered air purifying respirator system according to selected embodiments of the present disclosure depicted in FIGS. 9 and 10. [Figure 12] FIG. 12 is an exploded perspective view of the fan diffuser frame, fan diffuser, fan, and headgear-powered air-purifying respirator system according to selected embodiments of the present disclosure described in FIGS. 9 and 10 ; [Figure 13] FIG. 13 is a partial cross-sectional side view of the powered air-purifying respirator system according to selected embodiments of the present disclosure of FIGS. 9-12 , showing the airflow pattern through the breathable cover, the filter material, the fan, and into the area between the face shield and the wearer's face and foam cushion; [Figure 14] FIG. 14 is an exploded perspective view of a powered air-purifying respirator system according to selected embodiments of the present disclosure shown integratable with a welder's helmet; [Figure 15] FIG. 15 is a perspective front cutaway view of an alternative embodiment of a filter media of a powered air-purifying respirator system according to another selected embodiment of the present disclosure; [Figure 16] FIG. 16 is a perspective bottom view of a gasket or sealing of an alternative embodiment of a powered air purifying respirator system according to another selected embodiment of the present disclosure; [Figure 17] FIG. 17 is a perspective front side view of a powered air purifying respirator system according to another select embodiment of the present disclosure, showing an alternative embodiment filter media; [Figure 18] FIG. 18 is a perspective bottom side view of an alternative embodiment filter media according to another select embodiment of the present disclosure; [Figure 19] FIG. 19 is a cross-sectional view of an alternative embodiment filter media according to another select embodiment of the present disclosure; [Figure 20]FIG. 20 is a bottom perspective view of a face shield, main structure, fan assembly, and forehead cushion of a powered air purifying respirator system according to selected embodiments of the present disclosure; [Figure 21] FIG. 21 is a partial cross-sectional side view of the powered air-purifying respirator system according to selected embodiments of the present disclosure of FIGS. 9-12, 19, and 20, showing the internal fan diffuser, auxiliary fan diffuser, forehead cooling duct, and forehead cushion; [Figure 22] FIG. 22 is a top perspective view of a fan diffuser assembly and forehead cushion of a powered air purifying respirator system according to selected embodiments of the present disclosure; and [Figure 23] FIG. 23 is a perspective side view of a powered air purifying respirator system according to selected embodiments of the present disclosure shown in use and worn by a wearer or user with the addition of a hard hat.

[0036] It will be noted that the drawings presented are intended for illustrative purposes only, and as such, it is neither desired nor intended to limit the disclosure to any or all of the precise details of the structures shown, except as may be deemed essential to the claimed disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0037] In describing exemplary embodiments of the present disclosure, such as those shown in the figures, specific terminology is employed for the sake of clarity. However, the present disclosure is not intended to be limited to the specific terminology so selected, and it is understood that each specific element includes all technical equivalents that operate in a similar manner to achieve a similar function. However, the claimed embodiments may be embodied in many different forms and should not be construed as being limited to the examples described herein. The examples described herein are non-limiting examples and are merely examples of possible examples.

[0038] With regard to the above description, it is to be appreciated that optimal dimensional relationships, including variations in size, material, shape, form, location, movement mechanism, function and operation method, assembly and use are intended to be encompassed by the present disclosure.

[0039] 1-8, by way of non-limiting example, an exemplary embodiment of a face shield equipped with a powered air-purifying respirator system 100 according to this selected embodiment is illustrated. The face shield equipped with the powered air-purifying respirator system 100 may be used as an air-purifying respirator for the head H of a user or wearer W having a face F, forehead FH, and back of the head BH, and the face shield 1 provides the functionality of filtering smoke or fumes, filtering small particles, filtering a specific amount of viruses or bacteria, reducing and / or killing a specific amount of viruses, bacteria, or fungi, or affecting allergenicity, collectively, particulates P (cleaned air, cleanliness).

[0040] Referring again to FIGS. 1-6, in this embodiment, a face shield with a powered air-purifying respirator system 100 may comprise a face shield 1 configured to shield a user U's face F and block small and large particle droplets, splashes, sprays, or droplets (shield droplets) that may contain pathogens (viruses and bacteria) from entering the wearer's eyes, nose, or mouth. The face shield 1 may be formed or molded from a transparent or optically transparent material, and preferably is formed or molded as an optically transparent component, either as a single uniformly curved or double-curved transparent component ( FIG. 23 ) or as a pair of curved panels with a center seam 1A to maximize visibility through the face shield 1. The face shield 1 may be configured to block small and large particle droplets, splashes, sprays, or droplets (SP) that may contain pathogens (viruses and bacteria) from entering the wearer's eyes E, nose N, or mouth M (shield droplets).

[0041] The face shield 1 may include a face shroud 13 connected to the perimeter 1B of the face shield 1, preferably formed or shaped as an optically transparent component. Additionally, the face shroud 13 may be configured to provide a seal between the face shield 1 and the face F and chin C of the user U. The face shroud 13 may be configured to provide a seal between the face shield 1 and the face of the user U, forming a seal around the shroud perimeter 13A to block small and large particle droplets, splashes, sprays, or splashes (SP), which may contain pathogens (viruses and bacteria), from entering the wearer's eyes E, nose N, or mouth M around the sides of the face shield 1 or around the shield perimeter 1.1.

[0042] If it is desired to replace face shield 1 more frequently than the rest of the respirator due to scratches, etc., or if a higher grade of face shield protection is required, such as in abrasive applications, it is contemplated herein that face shield 1 may alternatively be made as a separate piece from filter cowl 2, outer perimeter flange 8, and face shroud 13 (described below).

[0043] It is contemplated herein that face shield 1 may be configured as a single horizontal curve without any vertical curves for ease of manufacturing, reduced manufacturing costs, and improved visualization.

[0044] The face shroud 13 may include a fan housing, conduit, or filtered air chamber 4 configured as a peak or visor-shaped structure with a filter cowl 2, such as an outer peripheral flange 8, having a rear peripheral flange edge 8A and a visor and front peripheral flange edge 8B. The outer peripheral flange 8 may be configured to receive and hold in place an outer filter media 7 about the outer peripheral flange 8. The filter cowl 2 and outer peripheral flange 8 provide support around the outer perimeter of the filter media 7, thus maximizing or increasing the surface area (in square inches / centimeters) of the filter media while keeping the overall profile of the respirator as small and lightweight as possible.

[0045] It is contemplated herein that the face shroud 13 may be elastic to fit around a variety of users and / or may be air permeable to allow air to escape from the mask area.

[0046] A face shroud 13 may be attached or connected around the periphery of the face shield 1, and the face shroud 13 is configured to provide a seal between the face shield 1 and the user's face, forming a seal around the respiratory tract and around the user's face to block small and large particle droplets, splashes, sprays, or splashes, which may contain pathogens (viruses and bacteria), from entering the wearer's eyes, nose, or mouth.

[0047] It is contemplated herein that the face shroud 13 and structure 10 may be manufactured as a single piece for ease of manufacturing, reduced manufacturing costs, and improved visualization.

[0048] It is further contemplated herein that the face shield 1, face shroud 13 and structure 10 may be combination parts configured to fit together for ease of manufacture, reduced manufacturing costs, cleaning and replaceability.

[0049] The face shroud 13 is configured to curve forward to accommodate the lower end 1A of the face shield 1 and provide a seal between the face shield 1 and the user's face (minimizing any gap between the face shield 1 and the wearer's chin C), and it is further contemplated herein that the face shield 1 may be configured as a single horizontal curve without any vertical curves for ease of manufacturing and improved visualization.

[0050] The face shroud 13 may be attached to the primary structure 10 via a snap mechanism, a hook-and-loop system, magnetic tape, or other means. It is contemplated herein that the filter cowl cover 14 may be part of the face shroud 13 or may be a separate component.

[0051] It is contemplated herein that the filtered air chamber 4 may have an anti-reflective cowl treatment 17, such as pre-printing or applying a secondary film to localized areas of the thermoformed sheet material, to the filtered air chamber 4 having a flat black or other dark colored anti-reflective coating or film applied, to make the back or underside of the primary structure 10 or filtered air chamber 4 non-reflective and used to reduce glare that may occur on the face shield 1 during use. Alternatively, the filtered air chamber 4 may include a secondary formed part having anti-reflective properties, masking the underside of the filtered air chamber 4 area and spraying an anti-reflective coating, pad printing an anti-reflective coating under the filtered air chamber 4 area of ​​a formed part, or dipping the filtered air chamber 4 portion of the primary structure 10 in an anti-reflective coating material.

[0052] It is further contemplated herein that the optional permeable filtering cowl cover 14 may be made of a breathable fabric, allowing the powered air-purifying respirator system 100 to have a less visible appearance to personal protective equipment. This may be valuable for the wearer to wear in public settings where pathogens are prevalent or where poor air quality, such as smoke, is present. Additionally, the permeable filtering cowl cover 14 may be removably attached to the primary structure 10 via a snap mechanism, a hook-and-loop fastener system, magnetic tape, or other means. Alternatively, for a powered air-purifying respirator system 100 designed as a disposable product, both the permeable filtering cowl cover 14 and the face shroud 13 may be permanently attached via adhesive, heat bonding, or the like.

[0053] It is contemplated herein that the filtered air chamber 4 or outer peripheral flange 8 may include one or more flange arch members extending or spanning across the filtered air chamber 4 to join two sides of the outer peripheral flange 8 and support the outer filter media 7.

[0054] While face shields comprising components of the powered air-purifying respirator system 100 can be manufactured by several methods, it is further contemplated herein that they may be constructed as a single piece, either thermoformed from transparent sheet materials such as PETG, polycarbonate, acrylic, butyrate, or injection molded from similar transparent resins or high-performance opaque materials for components not requiring transparency, as these materials offer a variety of forms and shapes and provide strength at reduced weight. However, it is contemplated herein that other suitable materials, etc., may be utilized, provided they have sufficient strength and / or durability to meet the objectives described herein to enable the use of face shields with the powered air-purifying respirator system 100.

[0055] Various changes in the materials used, shape, size, arrangement of parts, and parts connected by bolts, pins, screws, or similar fasteners or hinges or other rotating devices are understood herein without departing from the spirit of the claims herein.

[0056] It is further understood herein that parts and elements of the present disclosure may be arranged or positioned elsewhere based on one skilled in the art without departing from the present disclosure.

[0057] The outer filter media 7 may include filter media configured as a two-dimensional contour cut or flat shape that may fit into the outer peripheral flange 8 of the filter cowl 2. The advantage of this configuration is that it provides a large surface area of ​​filter media for filtration while eliminating the need for complex manufacturing and forming operations compared to other, more complex filters, such as cartridge-mounted pleated media, reducing filter and overall system costs. This filter design therefore alleviates supply constraints, particularly during high demand cycles during pandemics, reduces the overall cost of filter material, and allows maximum flexibility for utilizing alternative filter media in emergency situations. Preferably, the outer filter media 7 is configured with a straight rear filter edge 7A and a visor- or peak-shaped front filter edge 7B. An effective filter media may be capable of filtering smoke or plumes, filtering small particles, filtering specific amounts of viruses or bacteria, reducing and / or killing the amount of viruses, bacteria, or fungi, or affecting allergenicity. Additionally, the filter media may include coating technologies to reduce and / or kill microorganisms and may utilize nano- and micro-fiber layers to handle micro-scale droplets that evaporate into nano-scale aerosols that carry pathogens (viruses and bacteria).

[0058] It is contemplated herein that the filter media 7 may be attached to the outer peripheral flange 8 of the filter cowl 2 and may be made from several different woven or nonwoven types of filter media.

[0059] It is contemplated herein that adhesive seal 9 may be utilized to seal filter media 7 to outer peripheral flange 8. Additionally, adhesive seal 9 may be integral with filter media 7 or may be used to adhere filter media 7 to outer peripheral flange 8. Additionally, adhesive seal 9 may include a rear adhesive seal edge 9A and a front adhesive seal edge 9B.

[0060] It is further contemplated herein that the filter media 7 covers a relatively large surface area, and there is a significant volume within the filter chamber 4, thus potentially incorporating a pleated filter cartridge 38 or an activated charcoal (or any special performance filter media) filter cartridge 39. The pleated filter cartridge 38 or filter cartridge 39 may use the same sealing technique to the filter media via the outer peripheral flange 8 if higher filtration performance is required. The pleated filter cartridge 38 may be constructed utilizing a pleated filter media potting seal 43 that would be molded around the pleated filter media 44 during manufacture, and this seal would bond in the same manner as the two-dimensional filter media 7 bonds to the outer peripheral flange 8. Alternatively, the activated charcoal filter cartridge 38 may consist of an activated carbon filter media layer 40 laminated between an air permeable filter media layer 42 and an activated carbon filter three-dimensional seal 41.

[0061] It is recognized herein that the external filter media 7 allows for filtering of air before it enters the filtered air chamber 4, rather than an internal filter which contaminates the internal passageway (filtered air chamber 4) before filtration.

[0062] It is further recognized herein that the external filter media 7 is located external to the powered air purifying respirator system 100, allowing for quick changeover and easy replacement of the filter media 7, allowing for a variety of filter materials having nano- and micro-fiber layers to be utilized, and allowing for frequent rotation of the filter material to ensure that the filter material is always dry and free of bacteria, viruses, and particles.

[0063] It is further recognized herein that the outer filter media 7 provides increased filter surface area to provide adequate airflow through the filter material to provide positive air pressure adjacent the wearer's eyes, nose, and mouth.

[0064] It is further recognized herein that the filter cowl perimeter flange 8 may be formed as a single creased surface, allowing the filter media 7 and adhesive seal 9 to be applied without the need to distort either in three dimensions. It is envisioned that the adhesive seal 9 is replaceable, allowing the wearer to replace the filter media 7 as needed. In this preferred embodiment, it is envisioned that the adhesive seal 9 becomes part of the filter media 7 and may therefore be discarded along with the replaced filter media 7. New filter media 7 may have the adhesive seal 9 already attached to it, and it is envisioned that a backing film (not shown) may be removed from the filter media 7 to expose the adhesive seal 9, which will be positioned against the surface of the filter cowl 2 and the perimeter flange 8. These features of the filter cowl 2, outer perimeter flange 8, filter media 7, and adhesive seal 9 that comprise the powered air-purifying respirator system 100, with the possible exception of the hole features in the fan support 3 and the attachment means 35 for connecting the head strap 6, are designed to be moldable without requiring side actions in manufacturing tools. This novel approach reduces the cost and weight of the powered air-purifying respirator system 100.

[0065] The outer perimeter flange 8 may be provided with an adhesive, such as an adhesive seal 9, or hook-and-loop fastener, to allow for quick replacement and exchange of the outer filter media 7. In an alternative embodiment, the adhesive seal 9 may be adhered to the outer filter media 7 around the filter perimeter 7C to allow for quick replacement and exchange of the outer filter media 7. Features of the present disclosure may include the outer filter media 7 configured with a removable adhesive backer for adhering and sealing the outer filter media 7 to the filter cowl, and the outer perimeter flange 8 may include one or more flange arch members that extend across or bridge the fan duct 3A and the outer perimeter flange 8.

[0066] The filtered air chamber 4 may be formed as a single molding or may be integrally molded with the face shield 1. Additionally, the filtered air chamber 4 may include one wall as an inset, contour, or divot wall to accommodate or conform to the forehead FH of the wearer W and allow the powered air purifying respirator system 100 to rest on the forehead FH of the wearer W. Additionally, the filtered air chamber 4 may have a contour such as a conduit well 4A to draw or collect filtered air to the removable powered fan 11.

[0067] Additionally, the filter housing, such as the filtered air chamber 4, may include attachment means 6, such as slots, snaps, located on the upper left and right sides of the filtered air chamber 4, for releasably engaging the first strap end 34A and the second strap end 34B of the strap 34 to secure the adjustable strap 34 around the wearer's W head H and removably attach the powered air purifying respirator system 100 to the wearer's W forehead FH.

[0068] It is contemplated herein that the first strap end 34.1 and the second strap end 34.2 of the strap 34 may utilize attachment devices for adjusting the size of the strap, and may be configured with hook-and-loop fasteners, clasps, slots, hooks, or other similar attachment devices.

[0069] It is recognized herein that the attachment means 6 may be utilized to attach the powered air purifying respirator system 100 to headgear or a helmet that contacts at least a portion of the wearer's head H.

[0070] Powered fan 11 may include a single fan assembly or multiple fan assemblies removably affixed to filtered air chamber 4. Referring again to Figure 3, airflow AF is an arrow indicating the flow of air through powered air purifying respirator system 100. Powered fan 11 may have an integral power source or may be powered by a remote power source such as a belt-mounted battery pack or rechargeable battery 22, a solar panel, or the like.

[0071] Preferably, the headgear battery mount 23 carries or supports the rechargeable battery 22. The headgear battery mount 23 and rechargeable battery 22 are attached to the headgear 34 toward the back of the wearer's head so that the weight of these elements offsets the weight of the respirator.

[0072] Additionally, the electric fan 11 may be an axial fan assembly, which is commonly used in many products, especially electronics, and therefore manufactured in very high volumes, reducing costs and providing advantages from a manufacturing procurement perspective. The version shown is a standard 50 x 50 mm x 10 mm thick configuration with four corner mounting holes. However, other fan designs, such as radial or blower designs, could also be used. The electric fan 11 can be powered via a power cord 12, shown in this case as a USB cord that can plug into a standard battery module, which is readily available and commonly used to power mobile phones and tablet devices. However, other power systems could also be used.

[0073] Another optional battery mounting component may be utilized with the electric fans 11, such as a fan isolation gasket 15, which provides both air sealing and some electric fan 11 vibration damping that may primarily serve to reduce noise generated by the electric fans 11. The fan fasteners 16 are shown as screws (four per electric fan 11), although other fastening means could be used, such as rivets, heat stakes, double-sided adhesive, glue, and the like.

[0074] It is contemplated herein that the filtered air chamber 4 may be molded into the primary structure 10 .

[0075] It is contemplated herein that the filtered air chamber 4 includes a fan support 3, a forehead support wall 5, and an outer perimeter flange 8, which provides a fan plenum box for the powered fan 11 to allow efficient movement of the airflow AF, and may provide a large surface radius for the filter media 7.

[0076] The large arrow AF1 pointing to the top of the external filter media 7 represents unfiltered ambient air containing suspended particles P, while the small arrow AF2 shown in the filter chamber 4 represents filtered airflow moving through the fan duct 3A to the powered fan 11. The outlet air, medium arrow AF3, represents filtered airflow moving to the nose and mouth of the wearer W, located between the face shield 1 and the face shroud 13, and to the filter space between the wearer's face F and the face shield 1. The smallest arrow AF4 at the bottom of the face shield 1 and face shroud 13 discloses airflow exiting the air permeable face shroud 13 and exiting the powered air-purifying respirator system 100, thus creating a positive pressure condition in the space between the wearer's face and the face shield 1 and face shroud 13, preventing the wearer from being exposed to a potentially contaminated ambient environment and blocking smoke or fumes, small particles to be filtered, viruses or bacteria or fungi, or other allergenic substances from gaining access to the wearer's eyes, nose, or mouth.

[0077] It is further contemplated herein that an external filter media 7 may be placed outside the filtered air chamber 4 and the powered fan 11 to filter the large arrow AF1 before it enters the filtered air chamber 4 and the powered fan 11, protecting these areas from the polluted ambient environment and blocking smoke or fumes, filtering small particles, viruses or bacteria or fungi, or anything that may affect allergenicity.

[0078] The resilient air-permeable face shroud 13 may be an optional component to an existing powered air-purifying respirator system 100. It is contemplated herein that a face shield 1 without the external filter media 7, powered fan 11, and face shroud 13 may be configured to blow filtered air into the space between the wearer's face and the interior of the face shield, thereby protecting the wearer from exposure to a potentially contaminated ambient environment and creating a positive pressure condition that blocks smoke, fumes, filtering small particles, viruses, bacteria, fungi, or allergenic contaminants from gaining access to the wearer's eyes, nose, or mouth.

[0079] It is further contemplated herein that the face shroud 13 may be utilized in industrial and medical use settings where the face shroud 13 may prevent high speed moving particles and debris generated by operations such as cutting, grinding, sandblasting, lathing, etc. from overcoming the positive air pressure envelope generated by the powered air purifying respirator system 100.

[0080] 7 and 8 , the powered air purifying respirator system 100 can include a filter media compressed breathable cover 18, which may be permeable with a cover vent 19. The filter media compressed breathable cover 18 may be designed to provide compression to the filter media 7 all the way around the outer peripheral flange 8 of the filter media 7 to allow for quick replacement and exchange of the outer filter media 7. An optional filter media compressible gasket 29 may be utilized to enhance the seal between the filter media 7 and the outer peripheral flange 8. The optional filter media compressible gasket 29 may be either bonded or integrally molded to the outer peripheral flange 8 of the primary structure 30 or the filter media 7. The filter media compressed breathable cover 18 may be configured with a cover flange 20 along the perimeter of the cover, which may be utilized to secure the filter media compressed breathable cover 18 to the outer peripheral flange 8 of the primary structure 10 / 30. The filter media compressed breathable cover 18 may be molded with a cover snap latch 21 that allows the user or wearer W to release the filter media compressed breathable cover 18 to quickly replace the filter media 7.

[0081] The filter media compressed vent cover 18 is shown having a plurality of cover vents 19 located along the front and side edges of the filter media compressed breathable cover 18 to allow air flow into the filter media 7. It is contemplated herein that the plurality of cover vents 19 may be formed from any number of vent slots, rigid screen material, or permeable woven or nonwoven material.

[0082] It is contemplated in the specification that primary structure 30 is conceptually identical to primary structure 10 except for some mounting details and fan openings, and therefore some of the description of features relating to primary structure 10 will be used to describe primary structure 30.

[0083] The large arrow AF1 pointing to the multiple cover vents 19 in the filter media compressed breathable cover 18 and the small arrow AF1A represent unfiltered ambient air with suspended particles P traversing over the filter media 7, while the small arrow AF2 shown in the fan duct 3A represents filtered airflow moving through the fan duct 3A to the electric fan 11. The outlet air, the medium arrow AF3, represents filtered airflow through the fan diffuser 28 attached to the underside of the electric fan 11 toward the nose and mouth of the wearer W positioned between the face shield 1 and the face shroud 13, and toward the filter cavity between the wearer's face F and the face shield 1. The smallest arrow AF4 on the bottom of the face shield 1 and face shroud 13 discloses the airflow exiting the air permeable face shroud 13 and exiting the powered air purifying respirator system 100, thereby creating a positive pressure condition in the space between the wearer's face and the face shield 1 and face shroud 13, preventing the wearer from being exposed to a potentially contaminated ambient environment and blocking smoke or fumes, filtering small particles, viruses or bacteria or fungi, or allergenic impacts from gaining access to enter the wearer's eyes, nose, or mouth.

[0084] 9-13, there are illustrated, by way of example and not limitation, exemplary embodiments of a face shield fan and headgear assembly with a powered air-purifying respirator system 100A according to selected embodiments. The face shield with powered air-purifying respirator system 100A is utilized as an air-purifying respirator for a wearer W or user's head H, having a face F, forehead FH, and back of the head BH with the face shield 1, and can provide functions such as filtering smoke or fumes, filtering small particles, filtering specific amounts of viruses or bacteria, reducing and / or killing the amount of viruses, bacteria, or fungi, or affecting allergenic, collectively particulate matter P.

[0085] 9-12, a face shield with powered air purifying respirator system 100A of this fan and headgear assembly embodiment may have a face shield 1 configured to shield a wearer's face F to block small and large particle droplets, splashes, sprays, or droplets, which may contain pathogens (viruses and bacteria), from entering the wearer's eyes, nose, or mouth. The face shield 1 may be formed or molded from a transparent or optically transparent material, and is preferably formed or molded as an optically transparent component, formed as a single uniform curve or a pair of curved panels to maximize visibility through the face shield 1. The face shield 1 may be configured to block small and large particle droplets, splashes, sprays, or droplets (SP), which may contain pathogens (viruses and bacteria), from entering the wearer's eyes E, nose N, or mouth M.

[0086] The face shield 1 may include a face shroud 13 connected to the shield perimeter 1B of the face shield 1 and preferably formed or shaped as an optically transparent component. Additionally, the face shroud 13 may be configured to provide a seal between the face shield and the sides of the user's face F, chin C. The face shroud 13 may also be configured to provide a seal between the face shield 1 and the wearer's face F, forming a seal around the shroud perimeter 13A to block small and large particle droplets, splashes, sprays, or splashes (SP), which may contain pathogens (viruses and bacteria), from entering the wearer's eyes E, nose N, or mouth M around the sides or shield perimeter 1A of the face shield 1.

[0087] It is contemplated herein that face shield 1 may alternatively be made as a separate component from filter cowl 2, outer perimeter flange 8, and face shroud 13 (described below) if there is a desire to replace face shield 1 more frequently than other portions of the respirator due to scratches, etc., or if a higher grade of face shield protection is required, such as in abrasive applications.

[0088] It is contemplated herein that face shield 1 may be configured as a single horizontal curve with no vertical curves for ease of manufacturing, lower manufacturing costs, and improved visualization.

[0089] The face shroud 13 may include a fan housing, conduit, or filtered air chamber 4 configured as a canopy or visor-shaped structure with a filter cowl 2, such as an outer perimeter flange 8. The fan housing, conduit, or filtered air chamber 4 may be configured as a canopy or visor-shaped structure. The outer perimeter flange 8 may be configured to receive and hold in place an outer filter media 7 about the outer perimeter flange 8. The filter cowl 2 and outer perimeter flange 8 provide support around the outer perimeter of the filter media 7, thereby maximizing the surface area of ​​the filter media while keeping the overall profile of the respirator as small and lightweight as possible.

[0090] A face shroud 13 can be attached or connected around the periphery of the face shield 1 with the face shroud 13 configured to provide a seal between the face shield 1 and the face of the user, forming a seal around the respiratory tract and around the face of the user to block small and large particle droplets, splashes, sprays, or splashes that may contain pathogens (viruses and bacteria) from entering the wearer's eyes, nose, or mouth.

[0091] For ease of manufacturing, reduced manufacturing costs, and improved visualization, it is contemplated herein that the face shroud 13 and structure 30 may be manufactured as a single piece.

[0092] It is further contemplated herein that the face shield 1, face shroud 13, and structure 30 may be combination pieces configured to fit together for ease of manufacture, reduced manufacturing costs, cleaning, and replaceability.

[0093] It is further contemplated herein that the face shroud 13 is configured to curve forward to receive the lower end 1A of the face shield 1 and provide a seal between the face shield 1 and the user's face (minimizing the gap between the face shield 1 and the wearer's chin C), and that the face shield 1 can be configured as a single horizontal curve without vertical curves for ease of manufacturing and improved visualization.

[0094] The face shroud 13 may be attached to the primary structure 30 via a snap mechanism, a hook-and-loop system, magnetic tape, or other means. It is contemplated herein that the filter cowl cover 14 may be part of the face shroud 13 or may be a separate component.

[0095] It is contemplated herein that the filtered air chamber 4 may have an anti-reflective cowl treatment 17, such as pre-printing or applying a secondary film to localized areas of the thermoformed sheet material, to the filtered air chamber 4 having a flat black or other dark colored anti-reflective coating or film applied thereto, to render the back or underside of the primary structure 30 or filtered air chamber 4 non-reflective and to be used to reduce glare that may occur on the face shield 1 during use. Alternatively, the filtered air chamber 4 may include a secondary formed part having anti-reflective properties, masking the underside of the filtered air chamber 4 area and spraying an anti-reflective coating, pad printing an anti-reflective coating under the filtered air chamber 4 area of ​​a formed part, or dipping the filtered air chamber 4 portion of the primary structure 30 in an anti-reflective coating material.

[0096] It is further contemplated herein that the optional permeable filtering cowl cover 14 may be made of a breathable fabric, allowing the powered air-purifying respirator system 100A to have a less visible appearance to personal protective equipment. This may be valuable for the wearer to wear in public settings where pathogens are prevalent or where poor air quality, such as smoke, is present. Additionally, the permeable filtering cowl cover 14 may be removably attached to the primary structure 30 via a snap mechanism, a hook-and-loop fastener system, magnetic tape, or other means. Alternatively, for a powered air-purifying respirator system 100A designed as a disposable product, both the permeable filtering cowl cover 14 and the face shroud 13 may be permanently attached via adhesive, heat bonding, or the like.

[0097] It is contemplated herein that the filtered air chamber 4 or outer peripheral flange 8 may include one or more flange arch members extending or spanning across the filtered air chamber 4 to connect two sides of the outer peripheral flange 8 and support the outer filter media 7.

[0098] While the face shield comprising the components of powered air-purifying respirator system 100A can be manufactured by several methods, it is further contemplated herein that it may be constructed as a single piece, either thermoformed from a transparent sheet material such as PETG, polycarbonate, acrylic, butyrate, or injection molded from similar transparent resins, or more specifically high-density polyethylene or similar high-tensile or reinforced materials, because these materials offer a variety of forms and shapes and provide strength at reduced weight. However, it is contemplated herein that other suitable materials, etc., may be utilized, provided they have sufficient strength and / or durability to serve the purposes described herein for opening the face shield comprising powered air-purifying respirator system 100A into a chaise longue.

[0099] Various changes in the materials used, shape, size, arrangement of parts, and parts connected by bolts, pins, screws, or similar fasteners or hinges or other rotating devices are understood herein without departing from the spirit of the claims herein.

[0100] It is further understood herein that parts and elements of the present disclosure may be arranged or positioned in other locations based on one skilled in the art without departing from the present disclosure.

[0101] The outer filter media 7 may include filter media configured as a two-dimensional flat shape that may be fitted to the outer peripheral flange 8 of the filter cowl 2. The advantage of this configuration is that it provides a large surface area of ​​filter media for filtration while eliminating the need for complex manufacturing and forming operations compared to other, more complex filters, such as cartridge-fit pleated media, thereby reducing filter and overall system costs. This filter design therefore alleviates supply constraints, particularly during high demand cycles during pandemics, reduces the overall cost of filter material, and allows maximum flexibility for utilizing alternative filter media in emergency situations. Preferably, the outer filter media 7 is configured with a straight rear filter edge 7A and a visor- or peak-shaped front filter edge 7B. An effective filter media is capable of filtering smoke and plumes, filtering small particles, filtering specific amounts of viruses and bacteria, reducing and / or killing the amount of viruses, bacteria, or fungi, or affecting their allergenicity. Additionally, the filter media may include coating technologies to reduce and / or kill microorganisms and may utilize nano- and micro-fiber layers to handle micro-scale droplets that evaporate into nano-scale aerosols that carry pathogens (viruses and bacteria).

[0102] It is contemplated herein that the filter media 7 may be made from a number of different woven or nonwoven type filter media that are attached to the outer peripheral flange 8 of the filter cowl 2 .

[0103] It is further contemplated herein that the filter media 7 covers a relatively large surface area, and there is a significant volume within the filter chamber 4, thus potentially incorporating a pleated filter cartridge 38 or an activated charcoal (or any special performance filter media) filter cartridge 39. The pleated filter cartridge 38 or filter cartridge 39 may use the same sealing technique to the filter media via the outer peripheral flange 8 if higher filtration performance is required. The pleated filter cartridge 38 may be constructed utilizing a pleated filter media potting seal 43 that is molded around the pleated filter media 44 during manufacture, and this sealing would interface in the same manner as the two-dimensional filter media 7 does with the outer peripheral flange 8. Alternatively, the activated charcoal filter cartridge 38 may be constructed of an activated carbon filter media layer 40 laminated between an air permeable filter media layer 42 and an activated carbon filter three-dimensional seal 41.

[0104] It is recognized herein that the external filter media 7 allows for filtering of air before it enters the filtered air chamber 4, rather than an internal filter which contaminates the internal passageway (filtered air chamber 4) before filtration.

[0105] The specification further recognizes that the external filter media 7 is located external to the powered air purifying respirator system 100A, allowing for quick changeover and easy replacement of the filter media 7, allowing for a variety of filter materials having nano- and micro-fiber layers to be utilized, and allowing for frequent rotation of the filter material to ensure that the filter material remains dry and free of bacteria, viruses, and particles.

[0106] It is further recognized herein that the outer filter media 7 provides increased filter surface area to provide adequate airflow through the filter material to provide positive air pressure adjacent the wearer's eyes, nose, and mouth.

[0107] It is further recognized herein that the filter cowl perimeter flange 8 may be formed as a single creased surface, allowing the filter media 7 and adhesive seal 9 to be applied without the need to distort either in three dimensions. It is envisioned that the adhesive seal 9 is replaceable, allowing the wearer to replace the filter media 7 as needed. In this preferred embodiment, it is envisioned that the adhesive seal 9 becomes part of the filter media 7 and is therefore discarded along with the replaced filter media 7. A new filter media 7 may have the adhesive seal 9 already attached to it, and it is envisioned that a backing film (not shown) is removed from the filter media 7 to expose the surface of the filter cowl 2 and the adhesive seal 9 that is positioned against the perimeter flange 8. These features of the filter cowl 2, outer perimeter flange 8, filter media 7, and adhesive seal 9 that comprise the powered air purifying respirator system 100A, with the possible exception of the hole features of the dual fan support 3 and the attachment means 35 connecting the head strap 6, are designed to be formable without the need for side actions of production tools. This novel approach reduces the cost and weight of the powered air purifying respirator system 100A.

[0108] The outer perimeter flange 8 may be adhered with an adhesive, such as an adhesive seal 9, or a hook-and-loop fastener to allow for quick replacement and exchange of the outer filter media 7. In an alternative embodiment, the adhesive seal 9 may be adhered to the outer filter media 7 around the filter perimeter 7C to allow for quick replacement and exchange of the outer filter media 7. A feature of the present disclosure is the outer filter media 7 configured with a removable adhesive backer for adhering and sealing the outer filter media 7 to the filter cowl, the outer perimeter flange 8 may include one or more flange arch members that extend across or bridge the fan duct 3A, and the outer perimeter flange 8.

[0109] The filtered air chamber 4 may be formed as a single molding, or may be molded integrally with the face shield 1 to receive the fan diffuser assembly 24 configured to be separable from the face shield 1. Additionally, the filtered air chamber 4 may include one wall as an inset, contour, or divot wall, such as a forehead support wall 5, for receiving the forehead FH of the wearer W and allowing the powered air purifying respirator system 100A to rest on the forehead FH of the wearer W. Additionally, the filtered air chamber 4 may include a contour, such as a conduit well 4A, that draws or collects filtered air to the removable powered fan 11.

[0110] Furthermore, the fan diffuser assembly 24 may include attachment means 35, such as slots or snaps, located on the left and right (first and second) rear ends of the diffuser assembly 24 to releasably engage or connect the first strap end 34A and the second strap end 34B of the strap 34 to secure the strap 34 around the head H of the wearer W and removably attach the powered air purifying respirator system 100A to the forehead FH of the wearer W.

[0111] It is contemplated herein that the first strap end 34A and the second strap end 34B of the strap 34 may utilize attachment devices to adjust the size of the strap, and may be configured with hook-and-loop fasteners, clasps, slots, hooks, or other similar attachment devices.

[0112] It is recognized herein that the attachment means 35 may be utilized to attach the powered air purifying respirator system 100A to headgear or a helmet that contacts at least a portion of the wearer's head H.

[0113] In this second preferred embodiment, the fan diffuser assembly 24 carries dual or two electric fans 11, such as the first electric fan 11A and the second electric fan 11B, via a fan diffuser frame 25 having a latch assembly 26 and an eave-shaped assembly tab 27 for insertion therein, inset motion IM, where the latch assembly 26 latches into a mounting tab slot 32 that secures the fan diffuser assembly 24 to a main structure 30 having an eave-shaped cavity with a sliding and latching action. In this embodiment, the dual or two electric fans 11, such as the first electric fan 11A and the second electric fan 11B, are smaller than the fans of the first embodiment (FIGS. 1-8), at 40 x 40 x 10 mm, yet both move the same CFM of air. This arrangement provides a more compact design, resulting in closer spacing between the face shield 1 and the wearer's face.

[0114] Additionally, latch assembly 26 and assembly tabs 27 engage mounting means 31 and mounting tab slots 32, both of which are features of canopy-shaped cavity main structure 30, for a sliding and latching action to secure fan diffuser assembly 24 to canopy-shaped cavity main structure 30. Ideally, diffuser frame 25 would be molded with a flat black or other non-glare-inducing surface.

[0115] The dual electric fans 11A / 11B may have an integral power supply, or may be powered by a remote power source such as a belt-mounted battery pack or rechargeable battery 22, or may be powered by a solar panel or the like.

[0116] In this second preferred embodiment, the fan diffuser assembly 24 may include a diffuser frame 25 designed in a similar manner to the primary structures 10 and 30, and this design may be manufactured with few side actions or secondary processes during the manufacturing process. One or more fan diffusers 28 may be integrally formed with the fan diffuser frame 25 or may be formed separately. The fan diffuser fasteners 16 are shown as screws (four per fan diffuser 24) for attaching the fan diffusers 24, compression gasket 33, and electric fan 11 to the fan diffuser frame 25, although other fastening means such as rivets, heat-sealed posts, double-sided adhesive, glue, and the like could also be used.

[0117] The fan diffuser frame 25 may be utilized to direct filtered air from the at least one electric fan 11, or from the first electric fan 11A and the second electric fan 11B, such as slightly toward the face shield 1, to avoid the wearer W having the more direct airflow shown in the first preferred embodiment. It is contemplated herein that the fan diffuser 28 is rotatable so that the filtered air from the at least one electric fan 11, or from the first electric fan 11A and the second electric fan 11B, can be redirected in any direction between the face shield 1 and the face shroud 13.

[0118] It is contemplated herein that the fan filter assembly 24 may be inserted into the main structure 30 and latched thereto.

[0119] It is contemplated herein that the filtered air chamber 4 includes a fan support 3, a forehead support wall 5, and an outer perimeter flange 8, which provides a fan plenum box for dual electric fans 11 to allow efficient movement of airflow AF, and may provide a large surface radius for the filter media 7.

[0120] The optional arrangement includes an auxiliary fan diffuser duct 45 that redirects a small percentage of filtered air from at least one electric fan 11, or from the first electric fan 11A and the second electric fan 11B, towards the forehead FH of the wearer W to provide cooling to the forehead FH of the wearer W, thus improving comfort. This auxiliary fan diffuser duct 45 can be used in combination with an optional forehead cushion 46. The forehead cushion 46 is preferably formed from a porous material, such as open-cell polyurethane foam, to allow for the distribution of cooled air through the contact surface of the forehead cushion 46.

[0121] The large arrow AF1 pointing to the multiple cover vents 19 in the filter media compressed breathable cover 18 and the small arrow AF1A indicate unfiltered ambient air with suspended particles P traversing over the filter media 7, and the small arrow AF2 pointing to the fan conduit 4 represents the filtered air flow moving through the filtered air chamber 4 to the dual electric fans 11A / 11B. The outlet air represents filtered airflow that moves or is diverted through the fan diffuser ducts 28 and 45 in two directions, direction 1-AF3A) a portion of the dual electric fans 11A / 11B is output toward the forehead FH of the wearer W through the forehead cushion 46, and direction 2-AF3B) the remainder of the dual electric fans 11A / 11B is output toward the nose and mouth of the wearer W located between the face shield 1 and the face shroud 13, occupying the filter void between the wearer's face F and the face shield 1, thereby creating a positive pressure condition in the space between the wearer's face and the face shield 1 and face shroud 13, preventing the wearer from being exposed to a potentially contaminated ambient environment and blocking smoke or fumes, small particles to be filtered, viruses or bacteria or fungi, or anything that may have an allergenic effect from gaining access to enter the wearer's eyes, nose, or mouth.

[0122] Preferably, the headgear battery mount 23 carries or supports the rechargeable battery 22. The headgear battery mount 23 and rechargeable battery 22 are attached to the headgear 34 toward the back of the wearer's head so that the weight of these elements offsets the weight of the respirator.

[0123] Additionally, the dual electric fans 11A / 11B may be axial fan assemblies, which are commonly used in many products, particularly electronics, and therefore manufactured in very high volumes, reducing costs and providing advantages from a manufacturing procurement perspective. However, other fan designs, such as radial or blower designs, may also be used. The dual electric fans 11A / 11B may be powered via a power cord 12, shown in this case as a USB cord, which can plug into a standard battery module, readily available and commonly used to power mobile phones and tablet devices. However, other power systems may also be used.

[0124] Another optional battery mounting component may be utilized with the dual electric fans 11A / 11B, for example, a compression gasket 33 as a single assembly or a set of compression gaskets such as first compression gasket 33A and second compression gasket 33B as separate individual compression gaskets to provide sealing between the dual electric fans 11A / 11B, fan diffusers such as first fan diffuser 28A and second fan diffuser 28B, and fan support 3 of filter chamber 4, and also provide vibration damping that primarily helps reduce noise generated by the dual electric fans 11A / 11B.

[0125] An optional compression gasket 33 ensures sealing between the electric fan 11 and the fan support 3 of the filter chamber 4 which is a feature of the main structure 30 .

[0126] It is contemplated herein that the filtered air chamber 4 may be molded into the main structure 30 having dual mounting means 3A formed in the support 3 as openings for mating with and supporting the fan diffuser ducts 28 and 45 and the dual electric fans 11A / 11B, respectively.

[0127] It is further contemplated herein that an external filter media 7 is placed outside the filtered air chamber 4 and the dual electric fans 11A / 11B to filter the large arrow AF1 before it enters the filtered air chamber 4 and the dual electric fans 11A / 11B, keeping these areas free of contamination and blocking smoke or fumes, filtering small particles, viruses or bacteria or fungi, or anything that affects allergenicity.

[0128] The resilient air-permeable face shroud 13 may be an optional component to existing powered air-purifying respirator systems 100A. It is contemplated herein that face shield 1, without external filter media 7, dual electric fans 11A / 11B, and face shroud 13, may be configured to blow filtered air into the space between the wearer's face and the interior of the face shield, thereby protecting the wearer from exposure to potentially contaminated ambient environments and creating a positive pressure condition that blocks smoke, fumes, filtered small particles, viruses, bacteria, fungi, or allergenic contaminants from gaining access to the wearer's eyes, nose, or mouth.

[0129] It is further contemplated herein that the face shroud 13 may be utilized in industrial and medical use settings where the face shroud 13 may prevent fast moving particles and debris generated by operations such as cutting, grinding, sandblasting, lathing, etc. from overcoming the positive air pressure envelope generated by the powered air purifying respirator system 100A.

[0130] Referring to FIG. 11 , the powered air purifying respirator system 100A may include a filter media compressed breathable cover 18. The filter media compressed breathable cover 18 may be designed to provide compression to the filter media 7 around the entire perimeter of the filter media 7 up to the outer peripheral flange 8 to allow for rapid replacement and exchange of the outer filter media 7. An optional filter media compressible gasket 29 may be utilized to enhance the seal between the filter media 7 and the outer peripheral flange 8. The optional filter media compressible gasket 29 may be either bonded or integrally molded to the outer peripheral flange 8 of the primary structure 30 or the filter media 7. The filter media compressed breathable cover 18 may be configured with a cover flange 20 along the perimeter of the cover, which may be utilized to secure the filter media compressed breathable cover 18 to the outer peripheral flange 8 of the primary structure 10 / 30. A cover snap latch 21 may be molded into the filter media compressed breathable cover 18 to allow a user or wearer W to release the filter media compressed breathable cover 18 to quickly replace the filter media 7.

[0131] The filter media compressed breathable cover 18 is shown having a plurality of cover vents 19 located along the front and side edges of the filter media compressed breathable cover 18 to allow airflow to the filter media 7. It is contemplated herein that the plurality of cover vents 19 may be formed from any number of vent slots, rigid screen material, or permeable woven or nonwoven material.

[0132] It is contemplated herein that primary structure 30 is conceptually identical to primary structure 10, except for some mounting details and fan openings, and therefore some of the feature descriptions relating to primary structure 10 will be used to describe primary structure 30.

[0133] The large arrow AF1 pointing to the multiple cover vents 19 in the filter media compressed breathable cover 18 and the small arrow AF1A represent unfiltered ambient air with suspended particulates P traversing over the filter media 7, while the smaller arrow AF2 shown in the filtered air chamber 4 represents filtered airflow moving through the fan conduit 5 to the dual electric fans 11A / 11B. The outlet air, center arrow AF3, represents filtered airflow moving to the filter void between the wearer's nose N and mouth M, located between the face shield 1 and the optional face shroud 13, and between the wearer's face F and the face shield 1. The smallest arrow AF4 at the bottom of the face shield 1 and face shroud 13 discloses the airflow exiting the air permeable face shroud 13 and exiting the powered air purifying respirator system 100, thereby creating a positive pressure condition in the space between the wearer's face and the face shield 1 and face shroud 13, preventing the wearer from being exposed to a potentially contaminated ambient environment and blocking smoke, fumes, filtered small particles, viruses or bacteria or fungi, or allergenic impacts from gaining access to enter the wearer's eyes, nose, or mouth.

[0134] Referring again to FIG. 14, face shield 1 may be integrated with a welder's helmet to form powered air-purifying respirator system 100B. Powered air-purifying respirator system 100B may be configured by replacing main structure 10, 30 and face shield 1 with welding shield 36. Welding shield 36 is an opaque material for blocking welding sparks and flashes trajectory toward the wearer's face F. Additionally, welding shield 36 may be configured with lens aperture 36A configured to removably secure welding lens 37 thereto so that welding can be visualized while wearing powered air-purifying respirator system 100B. Additionally, powered air-purifying respirator system 100B may include other features listed above in FIGS. 1-13.

[0135] It is contemplated herein that the fan filter assembly 24 may be inserted into the main structure 30B and latched thereto.

[0136] It is further contemplated herein that the fan filter assembly 24 may provide a flow of cool air to the wearer's W-face F between the welding shield 36 and the wearer's W-face F through the fan filter assembly 24.

[0137] It is further contemplated herein that the fan filter assembly 24, filter media 7 may provide a positive pressure condition in the space between the wearer's face and the face shield 1 and face shroud 13, preventing the wearer from being exposed to a potentially contaminated ambient environment and blocking smoke, fumes, filtered small particles, viruses or bacteria or fungi, or allergenic impacts from gaining access to enter the wearer's eyes, nose, or mouth.

[0138] It is recognized herein that the fan filter assembly 24 and headgear 34 may include a pivoting or rotating connection of the attachment means 35 to allow the wearer W to tilt the welding shield 36 between a welding view (tilted down) and an inspection or alignment view (tilted up).

[0139] It is recognized herein that the powered air purifying respirator system 100B with weld shield 36 may include a filter media compression gasket 29, filter media 7, and a filter media compression breathable cover 18, as shown in FIG. 14.

[0140] 15 and 16, the structure 10 / 30 can be integrated with various filter media 7 for a powered air-purifying respirator system 100, such as an activated charcoal filter cartridge 39. The powered air-purifying respirator system 100 can be configured with an activated charcoal filter cartridge 39, 7A that integrates a filter media air permeable filter media layer 42 with an activated carbon filter media layer 40. The activated carbon filter media layer 40 can include a filter layer having granular activated carbon (GAC), which is a proven option for removing certain chemicals, particularly organic chemicals, chemicals that impart unpleasant odors or tastes, and other harmful contaminants or allergens, minimizing potential health hazards.

[0141] It is contemplated herein that an activated charcoal filter cartridge 39 may be integrated with the powered air purifying respirator system 100 as an alternative to the filter media 7 .

[0142] Additionally, the activated charcoal filter cartridge 39 may include an activated charcoal filter three-dimensional seal 41, which may be utilized to enhance the seal between the activated charcoal filter cartridge 39 and the outer peripheral flange 8 of the structure 10 / 30. The optional activated charcoal filter three-dimensional seal 41 may be either bonded or integrally molded to the outer peripheral flange 8 of the main structure 10 / 30 or the activated charcoal filter cartridge 39 for quick replacement of the activated charcoal filter cartridge 39.

[0143] Alternatively, the activated charcoal filter cartridge 38 may comprise a layer of activated charcoal filter media 40 laminated between a layer of air permeable filter media 42 and a three-dimensional activated charcoal filter seal 41 .

[0144] Referring to Figures 17, 18, and 19, the structure 10 / 30 may be integrated with various filter media 7B for a powered air-purifying respirator system 100, such as a pleated filter media cartridge 38. The powered air-purifying respirator system 100 may comprise a pleated filter media cartridge 38, 7B that integrates a pleated filter media 44 with a pleated filter three-dimensional seal 43. The pleated filter media cartridge 38 may configure the filter media in a folded pattern that allows the filter media to have additional surface area for filtering more particles, such as from a potentially contaminated ambient environment, blocking smoke, plumes, small particles, viruses, bacteria, or fungi, or allergenicity-impacting materials from gaining access to the wearer's eyes, nose, or mouth.

[0145] It is contemplated herein that pleated filter media cartridge 38 may be integrated with powered air purifying respirator system 100 as an alternative to filter media 7.

[0146] It is further contemplated herein that pleated filter cartridge 38, if higher filtration performance is desired, may utilize the same sealing approach to the filter media via outer peripheral flange 8. Pleated filter cartridge 38 may be constructed utilizing pleated filter media potting seal 43 that is molded around pleated filter media 44 during manufacture, and this sealing will interface in the same manner as two-dimensional filter media 7 does with outer peripheral flange 8.

[0147] Additionally, the pleated filter media cartridge 38 may include a pleated filter three-dimensional seal 43, which may be utilized to enhance sealing between the configured pleated filter media cartridge 38 and the outer peripheral flange 8 of the main structure 10 / 30. The optional pleated filter three-dimensional seal 43 may be either bonded or integrally molded to the outer peripheral flange 8 of the main structure 10 / 30 or the pleated filter media cartridge 38 for quick replacement of the activated charcoal filter cartridge 39.

[0148] 9-13 and now FIG. 20-22, a powered air-purifying respirator system 100A may include a face shield 1 and dual electric fans 11A / 11B configured in a fan diffuser frame 25, each pushing or blowing filtered air through a fan diffuser, e.g., first fan diffuser 28A and second fan diffuser 28B, which direct airflow AF3B between the wearer's face F and the face shield 1, and an auxiliary fan diffuser duct 45, which directs a small percentage of the filtered air AF3A toward the wearer's forehead FH to provide cooling for the wearer's forehead FH and thus improve comfort. This auxiliary fan diffuser duct 45 may be used in combination with an optional forehead cushion 46. The forehead cushion 46 is preferably formed of a porous material, such as polyurethane foam, to allow for the dispersion of cooled air through the contact surface of the forehead cushion 46.

[0149] Thus, in another aspect, the present disclosure can be configured such that air is drawn through a filter media located in the outer brow region of the face shield via a powered fan mounted between the filter media and above the plane of the wearer's brows.

[0150] Thus, in another aspect, the present disclosure may be configured such that filtered air is blown into the space between the wearer's face and the interior of the face shield, thereby creating a positive pressure condition that protects the wearer from exposure to potentially contaminated ambient conditions.

[0151] Thus, in another aspect, the present disclosure may be configured such that the barrier allows air to vent through the shroud, but can also serve to filter potential pathogens before the wearer's exhaled breath and, therefore, exhausts to the environment. In applications not requiring exhaled breath filtration, the shroud can also protect the wearer from flying dust and debris, and provide side and back splash, spray, or splash protection in some scenarios that may overwhelm the positive pressure envelope.

[0152] 23, this embodiment of the fan and headgear assembly for a face shield with a powered air-purifying respirator system 100C may include a face shield 1 configured with a double-ruled surface, a face shroud 13, a filter media compressed breathable cover 18 with cover vents 19 covering the main structure 10 / 30, a fan diffuser 28 that draws air through the filter media 7 as described above in FIGS. 1-22, and a filter chamber 4 with a fan filter assembly 24 having a powered fan 11. In this embodiment, the powered air-purifying respirator system 100C is integrally or removably attached to a hard hat 50 or hard hat visor 51, or alternatively, is pivotally attached to the hard hat 50 by attachment means 31A, allowing for tilting of the powered air-purifying respirator system 100C up and down relative to the attachment means 31A and the hard hat 50. Additionally, the hard hat 50 may include hearing protectors 48 attached to the hard hat 50 to provide noise-reducing hearing protection to the wearer W. Hearing protector 48 includes a pivotable mounting means 48A that allows hearing protector 48 to be pivoted up and down, and is used for hearing protection in a prone position and for conversation when pivoted upward.

[0153] It is contemplated herein that the powered air purifying respirator system 100C may be integrated into or affixed to other types of headwear.

[0154] Next, with regard to the above description, it should be recognized that optimal dimensional relationships are intended to be encompassed by the present disclosure, including variations in size, material, shape, form, location, movement mechanism, function, and method of operation, assembly, and use.

[0155] The foregoing description and drawings constitute exemplary embodiments. While exemplary embodiments have been described in this manner, those skilled in the art should note that the disclosure is illustrative only, and that various other alternatives, adaptations, and modifications may be made within the scope of the claims of the present disclosure. The mere listing or numbering of steps in a method in a particular order does not in any way limit the order of steps in the method. Numerous modifications and other embodiments will occur to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Although specific terms may be used herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Moreover, while the present disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the spirit and scope of the disclosure as defined by the appended claims. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein, but rather is limited only by the scope of the following claims.

Claims

1. 1. An air-purifying respirator for a user's head, including the face and forehead, to deliver filtered air and provide a droplet shield, the air-purifying respirator comprising: a face shield configured to shield the user's face from the droplets; and a powered air purification system; The powered air cleaning system comprises: at least one fan configured to provide positive air pressure between the face shield and the user's face; a fan housing positioned adjacent an upper edge of the face shield, the fan housing includes a fan support, a forehead support wall, and a filter cowl having an outer peripheral flange to form a single crease surface; the outer peripheral flange having a front peripheral flange edge configured as a visor and an arched rear peripheral flange edge located rearward and above the front peripheral flange edge; the fan housing, the front peripheral flange edge configured to support the fan therein and enable efficient movement of the air; a head strap attached to the fan housing, the head strap configured to encircle at least a portion of the user's head, the head strap configured to support the fan housing; and a filter media configured as a two-dimensional flat shape that provides a visor-shaped surface area for the filter media while minimizing the overall size of the air-purifying respirator, the filter media being capable of being fitted into the outer peripheral flange of a filter cowl; the fan pulls air through the filter media and the fan pushes the filtered air out of the fan housing between the face shield and the user's face as the positive air pressure.

2. 10. The air-purifying respirator of claim 1, further comprising a face shroud connected to a periphery of the face shield, the face shroud configured to provide a seal between the face shield and the face of the user.

3. 10. The respirator of claim 1, wherein the filter media, the at least one fan, and the fan housing deliver a positive pressure of the filtered air between the face shield and the face of the user.

4. 10. The air-purifying respirator of claim 1, wherein the face shield is configured as a single horizontal curve to maximize visibility.

5. 10. The air purifying respirator of claim 1, wherein the fan housing is configured as a visor shape.

6. 10. The air purifying respirator of claim 1, wherein the head strap is adjustable in length around the fan housing.

7. 3. The air purifying respirator of claim 2, wherein the face shroud is resiliently configured to fit around the user's face.

8. 3. The air-purifying respirator of claim 2, wherein the face shroud is configured to be air permeable to allow filtered air to exit, thereby maintaining a positive air pressure in a space between the face shield and the user's face.

9. 10. The air purifying respirator of claim 1, further comprising a permeable filter cover disposed over the filter media, removably attached to the outer peripheral flange, and configured to compress against the outer peripheral flange to improve a seal.

10. 10. The air purifying respirator of claim 1, wherein the fan housing is contoured on one side to accommodate the user's forehead.

11. 3. The air-purifying respirator of claim 2, wherein the fan draws air into the fan housing through the filter media, and the fan pushes the filtered air toward the user between the face shield and the face shroud.

12. 10. The air purifying respirator of claim 1, further comprising an adhesive seal affixed to the filter media for removably mounting the filter media to the outer peripheral flange of the filter cowl.

13. 10. The air purifying respirator of claim 1, wherein the fan housing further includes attachment means for releasably connecting the head strap thereto.

14. 10. The air purifying respirator of claim 1, further comprising a power cord connected to the fan.

15. 15. The air purifying respirator of claim 14, further comprising a battery mount affixed to the head strap, the battery mount configured to secure a battery thereto and connect to the power cord.

16. 11. The air purifying respirator of claim 10, further comprising a fan diffuser duct configured to direct a portion of the filtered air towards the user's forehead to provide cooling.

17. 17. The air purifying respirator of claim 16, wherein the fan housing is configured with a forehead cushion.

18. 18. The air purifying respirator of claim 17, wherein the forehead cushion is air permeable, and wherein the forehead cushion is configured to receive the portion of the filtered air.

19. 10. The air-purifying respirator of claim 1, wherein the fan, the fan housing, and the head strap are configured to be separable from the face shield.

20. 10. The air-purifying respirator of claim 1, wherein the face shield is formed of a transparent material.

21. 10. The air-purifying respirator of claim 1, wherein the face shield is formed of a non-transparent material.

22. 22. The air-purifying respirator of claim 21, wherein the face shield further comprises a welding lens configured within the face shield.

23. 1. An air-purifying respirator for a user's head, including the face and forehead, to deliver filtered air and provide a droplet shield, the air-purifying respirator comprising: a hard hat having a visor; a powered air cleaning system located adjacent to the visor, The powered air cleaning system comprises: a face shield configured to shield the user's face from the droplets; at least one fan configured to provide positive air pressure between the face shield and the user's face; a fan housing positioned adjacent an upper edge of the face shield, the fan housing having a fan support, a forehead support wall, and a filter cowl having an outer peripheral flange to form a single crease surface; the outer peripheral flange having a front peripheral flange edge configured as the visor and an arched rear peripheral flange edge positioned rearward and above the front peripheral flange edge; the front peripheral flange edge and the rear peripheral flange edge together form an outer peripheral flange; the fan housing, the front peripheral flange edge configured to support the fan therein and enable efficient movement of the air; a filter media configured as a two-dimensional flat shape that provides a visor-shaped surface area for the filter media while minimizing the overall size of the air-purifying respirator, the filter media being capable of being fitted into the outer peripheral flange of the filter cowl; the fan pulls air through the filter media and the fan pushes the filtered air out of the fan housing between the face shield and the user's face as the positive air pressure.

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