Respiratory system with a permeable neck seal

Abstract

The invention is a respirator system which includes a respiratory hood defining an air cavity for a user wearing the respiratory hood, the air cavity having an inlet connectable to a source of breathable air and an outlet arranged to deliver breathable air to a face region of the user. The respiratory hood includes a visor and a permeable media positioned at a neck seal portion of the respiratory hood to egress air from the air cavity. The respiratory system also includes a suspension system configured to interface with the user's head.

Description

[0001] RESPIRATORY SYSTEM WITH A PERMEABLE NECK SEAL

[0002] BACKGROUND

[0003] Generally, this disclosure relates to respirators that are worn on a user’s head to provide breathable air for the user.

[0004] Respirators are well known and have many uses. For example, respirators may be used to allow the user to breathe safely in a contaminated atmosphere, to aid breathing of a user in an environment containing dusts, fumes, vapors, and / or gases, in a toxic atmosphere, or in a laboratory. Respirators may also be worn where it is desired to minimize contamination of the surrounding atmosphere, such as when a user is working in a clean room.

[0005] Respirator systems come in a wide range of types and sizes and may be used for a variety of purposes. Respirator systems include, without limitation, respirator hoods that usually include a soft, flexible material suitable for the environment in which it is to be worn. Hoods of this type are commonly used with a bodysuit to isolate the user from the environment in which the user is working. The respiratory hood has a transparent region at the front, commonly referred to as a visor, through which the user can see. The visor may be an integral part of the hood or detachable so that it can be removed and replaced if damaged.

[0006] The respirator hood is intended to provide an air cavity for a user. As such, the hood is also typically sealed about the user’s head and / or neck area, and at least one air supply provides breathable air to the interior of the respirator hood.

[0007] SUMMARY

[0008] One embodiment of the invention is a respirator system which includes a respiratory hood defining an air cavity for a user wearing the respiratory hood, the air cavity having an inlet connectable to a source of breathable air and an outlet arranged to deliver breathable air to a face region of the user. The respiratory hood includes a visor and a permeable media positioned at a neck seal portion of the respiratory hood to egress air from the air cavity. The respiratory system also includes a suspension system configured to interface with the user’s head.

[0009] Various aspects and advantages of exemplary embodiments of the disclosure have been summarized. This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, is not intended to describe each disclosed embodiment or every implementation of the claimed subject matter, and is not intended to be used as an aid in determining the scope of the claimed subject matter. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The figures and the description that follow more particularly exemplify illustrative embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1A is a side elevation of a respirator system, with a respirator hood shown in phantom.

[0011] FIG. IB is a top view of the respirator system of FIG. 1 A, with the hood removed for clarity of illustration.

[0012] FIG. 2A is a side elevation of another respirator system, with a respirator hood shown in phantom.

[0013] FIG. 2B is a top view of the respirator system of FIG. 2A, with the hood removed for clarity of illustration.

[0014] FIG. 3A is a bottom perspective view of the permeable media doubled over to form a tunnel cavity comprising a drawstring at a neck seal portion of the respiratory hood.

[0015] FIG. 3B is a bottom perspective view of the permeable media doubled over to form a tunnel cavity comprising an elastic band at a neck seal portion of the respiratory hood.

[0016] FIG. 3C is a bottom perspective view of a single layer permeable media comprising a drawstring at a neck seal portion of the respiratory hood.

[0017] FIG. 4A is a bottom view of an exemplary respirator system wherein a drawstring is in a slackened position within the tunnel cavity.

[0018] FIG. 4B is a perspective view of an exemplary respirator system illustrating the permeable tunnel cavity when viewed in through a visor of the respiratory hood relative to the user wherein the drawstring is in a slackened position within the tunnel cavity.

[0019] FIG. 4C is a sideways perspective view from the bottom of an exemplary respiratory hood illustrating the permeable tunnel cavity relative to a user wherein the drawstring is in a slackened position within the tunnel cavity.

[0020] FIG. 5 is a bottom view of an exemplary respirator system wherein the drawstring is in a tightened position within the tunnel cavity.

[0021] FIG. 6 is a perspective view of an exemplary respirator system illustrating the permeable tunnel cavity when viewed in through a visor of the respiratory hood.

[0022] FIG. 7 is a sideways perspective view from the bottom of an exemplary respiratory hood illustrating the permeable tunnel cavity relative to a user wherein the drawstring is in a tighten position within the tunnel cavity.

[0023] FIG. 8 is a side perspective view of an exemplary respiratory hood, according to an embodiment of the present invention that includes a shroud.

[0024] FIG. 9 is a side perspective view of the respiratory hood showing the flow of air, according to an embodiment of the present invention that includes a first and second shroud.

[0025] While the above-identified figures set forth one or more embodiments of the disclosed subject matter, other embodiments are also contemplated, as noted in the disclosure. In all cases, this disclosure presents the disclosed subject matter by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this disclosure.

[0026] DETAILED DESCRIPTION

[0027] In describing preferred embodiments of the invention, specific terminology is used for the sake of clarity. The invention, however, is not intended to be limited to the specific terms so selected, and it is to be understood that each term so selected includes all technical equivalents that operate similarly.

[0028] Glossary

[0029] The terms set forth below will have the meanings as defined:

[0030] Respiratory hood means a loose-fitting face piece that covers at least a face of the user.

[0031] Non-shape stable means a characteristic of a structure whereby that structure may assume a shape, but is not necessarily able, by itself, to retain that shape without additional support.

[0032] Shape stable means a characteristic of a structure whereby that structure has a defined shape and is able to retain that shape by itself, although it may be flexible.

[0033] Air cavity means the space around at least a user’s nose and mouth where air may be inhaled. Shell means a barrier that separates an interior of a respirator, including at least the air cavity, from the ambient environment of the respirator. A hood can serve as a shell.

[0034] Removable means that a part can be connected and disconnect to another structure without causing damage to either structure. Tools may or may not be required to accomplish the connection or disconnection.

[0035] Manifold means an air flow plenum having an air inlet and having one or discrete air conduits in communication with the air inlet, with each air conduit having at least one air outlet.

[0036] Permeable means that a gas (e.g., air) can pass through a material. Often, a permeable media is a nonwoven fabric, such as a spunbond fabric.

[0037] A respirator system 10 is illustrated in FIG. 1A. In this instance, the respirator system 10 includes a non-shape stable respiratory hood 12 that serves as a shell for the respirator system 10 and that, for clarity of illustration in FIG. 1A, is shown by phantom lines. A top view of the respirator system 10 is shown in FIG. IB. The respirator system 10 further includes a head suspension system 14 that is adjustable in one or more dimensions so that it may be sized to conform to a head 16 of a user 18. The respiratory hood 12 is sized to extend over at least a front and top of the head 16 of the user 18, if not over the entire head 16.

[0038] The respirator system 10 further comprises a shape stable air manifold 20. The manifold 20 is removably supported by the suspension system 14 at a plurality of points such as attachment points 22 and 24 in FIG. 1A. The suspension system 14 and manifold 20 are secured together by suitable mechanical fasteners, such as detents, clips, snaps, or two part mechanical fasteners (e.g., hook and loop fasteners). In one embodiment, the suspension system 14 and manifold 20 are separable via such fasteners. When connected and mounted on a user’s head 16 as illustrated in FIG. 1A, the suspension system 14 supports the manifold 20 in a desired position relative to the user’s head 16.

[0039] As seen in FIGS. 1A and IB, the air manifold 20 has an air inlet conduit 26 and a plurality of air delivery conduits 27 and 28 (in FIG. IB, two of the delivery conduits 28a and 28b are illustrated). In one embodiment, the air inlet conduit 26 is disposed adjacent a back of the user’s head 16. The air inlet conduit 26 is mostly covered by an outer device 46. The air inlet conduit 26 is in fluid communication with the air delivery conduit 27. The air delivery conduit 27 includes an air distribution chamber 30 and is in turn in fluid communication with each air delivery conduit 28. The air delivery conduit 27 and its air distribution chamber 30 are also disposed adjacent the back of the user’s head 16, and as the air delivery conduits 28 extend forwardly therefrom, they curve and split to provide separate left and right conduits for the flow of air therethrough. Each air delivery conduit 28 has an air outlet 32 (e.g., air outlet 32a of air delivery conduit 28a and air outlet 32b of air delivery conduit 28b). In one embodiment, each air outlet 32a and 32b is adjacent a facial area 34 of the head 16 of the user 18. While only two air delivery conduits 28 are illustrated on the manifold 20 in FIGS. 1A and IB, it is understood that any number (e.g., one, two, three, etc.) of such conduits may be provided. Further, in some embodiments, a manifold may have one or more outlets of respective air delivery conduits adjacent a user’s forehead and one or more air outlets of respective air delivery conduits adjacent a user’s nose and mouth (e.g., on each side of the user’s nose and mouth).

[0040] Valve 51 (FIG. IB) is another air outlet located at the juncture of the left and right air delivery conduits. Air flow from valve 51 travels up the back of the user’s head 16, as illustrated by arrow 56 in FIG. 1A.

[0041] The respiratory hood 12 includes a visor 36 disposed on a front side thereof through which a user 18 can see. In one embodiment, (see, e.g., FIG. 1A), an interior portion of the visor 36 (or an interior portion of the respiratory hood) is releasably affixed to a tab portion 37 of the suspension system 14, on each side of the user’s facial area 34. The respiratory hood 12 is thus supported adjacent its front side by the suspension system 14. On its back side, the respiratory hood 12 includes an air inlet opening 38 (FIG. 1A). The air inlet conduit 26 of the manifold 20 extends through the air inlet opening 38 and is in fluid communication with a supply of breathable air via an breathing tube 40 attached to the air inlet conduit 26 (that attachment being, as shown in the embodiment of FIG. 1A, outside of the respiratory hood 12). Optionally, the hood 12 comprises a breathing tube cover 80 disposed on the breathing tube 40, the breathing tube cover 80 comprising a first end 81 and a second end 82, wherein the first end 81 is elastic, and the second end 82 is open. The breathing tube 40 is in turn connected to a supply 42 of breathable air for the user 18. Such a supply 42 may take the form of a pressurized tank of breathable air, a powered air-purifying respirator (PAPR) or a supplied breathable air source, as is known. The air flows from the supply 42 through breathing tube 40 and into the air inlet conduit 26 of the manifold 20. The air then flows through the air distribution chamber 30 of the air delivery conduit 27 and into each of the air delivery conduits 28. Air flows out of each conduit 28 from its air outlet 32 and into an air cavity 44 defined by the respiratory hood 12 about the head 16 of the user 18. Breathable air is thus delivered by the manifold 20 to the user’s facial area 34 for inhalation purposes which, in some embodiments, includes not only the space around the user’s nose and mouth where air may be inhaled, but also other areas about the user’s face such as around the user’s eyes and forehead.

[0042] Because of the introduction of such air, the air pressure within the respiratory hood 12 typically may be slightly greater than the air pressure outside the respiratory hood. Thus, the respiratory hood 12 can expand generally to the shape illustrated in FIG. 1A about the user’s head 16, manifold 20, and suspension system 14. The respirator system 10 thus provides the user 18 with an air cavity 44 within the non-shape stable respiratory hood 12, with the air delivered adjacent the user’s face by the shape stable manifold 20.

[0043] Another respirator system 10 is illustrated in FIG. 2A. In this instance, the respirator system 10 includes a non-shape stable respiratory hood 12 that serves as a shell for the respirator system 10 and that, for clarity of illustration in FIG. 2A, is shown by phantom lines. A top view of the respirator system 10 is shown in FIG. 2B. The respirator system 10 further includes a head suspension system 14 that is adjustable in one or more dimensions so that it may be sized to conform to a head 16 of a user 18. The respiratory hood 12 is sized to extend over at least a front and top of the head 16 of the user 18, if not over the entire head 16. The air space between the head 16 of a user 18 and the respiratory hood 12 provides a ducted area. Supplied air pressurizes the respiratory hood 12 such that the respiratory hood 12 inflates and allows airflow across the face region 34 of the user 18.

[0044] FIG. 3A illustrates a permeable media 60 that is doubled over to form a tunnel cavity 61 at a neck seal portion of the respiratory hood 12. Herein collectively referred to as a permeable tunnel cavity 63. The permeable tunnel cavity 63 is attached to the respiratory hood 12 by means of stitching, ultrasonic welding, or heat welding, for instance. In this embodiment, a drawstring 62 is positioned through the permeable tunnel cavity 63 for the purpose of providing a means of securing the permeable tunnel cavity 63 positioned on the respiratory hood 12 to a neck 19 of a user 18. The permeable tunnel cavity 63 once secured to the neck 19 of the user 18 acts as a neck seal, closing off the inside of the respiratory hood 12 and defining the air cavity 44. The breathable air flowing into the air cavity 44 from the supply 42 of breathable air and the air exhaled by the user 18 within the air cavity 44 egresses out of the air cavity 44 through the permeable tunnel cavity 63 positioned at the neck seal portion of the respiratory hood 12.

[0045] FIG. 3B illustrates an embodiment wherein a permeable media 60 is doubled over to form a tunnel cavity 61 at a neck seal portion of the respiratory hood 12. Herein collectively referred to as a permeable tunnel cavity 63. The permeable tunnel cavity 63 is attached to the respiratory hood 12 by means of stitching, ultrasonic welding, or heat welding, for instance. In this embodiment, an elastic band 64 is positioned through the permeable tunnel cavity 63 for the purpose of providing a means of securing the permeable tunnel cavity 63 on the respiratory hood 12 to the neck 19 of a user 18. The permeable tunnel cavity 63 once secured to the neck 19 of the user 18 acts as a neck seal, closing off the inside of the respiratory hood 12 and defining the air cavity 44. The breathable air flowing into the air cavity 44 from the supply 42 of breathable air and the air exhaled by the user 18 within the air cavity 44 egresses out of the air cavity 44 through the permeable tunnel cavity 63 positioned at the neck seal portion of the respiratory hood 12.

[0046] FIG. 3C illustrates an embodiment where a single layer of permeable media 60 is located at a neck seal portion of the respiratory hood 12. The layer of permeable media 60 is attached to the respiratory hood 12 by means of stitching, ultrasonic welding, or heat welding, for instance. In this embodiment, a drawstring 62 is attached to the layer of permeable media 60, e.g., by folding over a portion of the permeable media 60 and sewing it to itself to form a channel 67 for the drawstring 62, for the purpose of providing a means of securing the permeable media 60 on the respiratory hood 12 to the neck 19 of a user 18. As an alternative to the drawstring 62, an elastic band could be employed. The permeable media 60 once secured to the neck 19 of the user 18 acts as a neck seal, closing off the inside of the respiratory hood 12 and defining the air cavity 44. The breathable air flowing into the air cavity 44 from the supply 42 of breathable air and the air exhaled by the user 18 within the air cavity 44 egresses out of the air cavity 44 through the permeable media 60 positioned at the neck seal portion of the respiratory hood 12.

[0047] FIG. 4A illustrates a bottom of the respiratory hood 12 when a drawstring 62, passing through the permeable tunnel cavity 63, is in a slackened position. Ideally, a user 18 would don the respiratory hood 12 over the head 16 of the user 18 when the drawstring 62 is in the slackened position, as seen in FIG. 4B, which illustrates the permeable tunnel cavity 63 relative to the face region 34 of the user 18 after the user 18 has worn the respiratory hood 12. FIG. 4C illustrates the permeable tunnel cavity 63 relative to the neck 19 of the user 18 after the user 18 has worn the respiratory hood 12 when the drawstring 62 is in a slackened position within the tunnel cavity 63.

[0048] FIG. 5 illustrates a bottom view of an exemplary respirator system 10 when the drawstring 62, passing through the permeable tunnel cavity 63, is in a tightened position. The pulling of the drawstring 62 secures permeable tunnel cavity 63, and by extension the respiratory hood 12, against the neck 19 of the user 18. The permeable tunnel cavity 63 once secured to the neck 19 of the user 18 acts as a neck seal, closing off the inside of the respiratory hood 12 and defining the air cavity 44. The breathable air flowing into the air cavity 44 from the supply 42 of breathable air and the air exhaled by the user 18 within the air cavity 44 egresses out of the air cavity 44 through the permeable tunnel cavity 63 positioned at the neck seal portion of the respiratory hood 12.

[0049] FIG. 6 is another view, which illustrates the permeable tunnel cavity 63 when the drawstring 62 is in the tightened position when viewed in through a visor of the respiratory hood 12. FIG. 7 illustrates the drawstring in a tightened position within the permeable tunnel cavity 63 relative to the neck 19 of the user 18.

[0050] FIG. 8 illustrates an embodiment of the respiratory hood 12, comprising a shroud 70 configured to be worn by the user 18 under the respiratory hood 12. The permeable member is positioned at the neck seal portion of the respiratory hood 12 beneath the shroud 70 and doubled over to form a tunnel cavity 63. Placement of the permeable tunnel cavity 63 at the neck seal portion of the respiratory hood 12 beneath the shroud 70 ensures that air egressing from the air cavity 44 egresses beneath the shroud 70. This is advantageous when working in ISO 8 cleanroom environments, where it is beneficial to have the air from within the air cavity 44 egress away from a work area. This minimizes contamination of the work area caused by the egressed air coming in contact with the work area. Examples of ISO 8 cleanroom applications are pharmaceutical cleanrooms, medical device cleanrooms, biotech cleanrooms, and lifescience cleanrooms.

[0051] In another embodiment the respiratory hood 12 comprises a shroud 70 wherein the shroud 70 is a first shroud 70 and the respirator system 10 further comprises a second shroud 71 configured to be worn by the user 18 under the respiratory hood 12 and over the first shroud 70. The permeable tunnel cavity 63 at the neck seal portion of the respiratory hood 12 is positioned to egress air between the first shroud 70 and the second shroud 71. This is advantageous when working in ISO 8 or lower cleanroom environments, where it is beneficial to have the air from within the air cavity 44 egress away from a work area. This minimizes contamination of the work area caused by the egressed air coming in contact with the work area.

[0052] FIG. 9 illustrates the flow of air within the respirator system 10. The air, delivered to the face region 34 of the user 18 and into the air cavity 44 of the respiratory hood 12 from the air source, egresses out of the air cavity 44 via the permeable tunnel cavity 63 at the neck seal portion around the neck 19 of the user 18 between the first shroud 70 and the second shroud 71.

[0053] Typically, the respiratory hood 12 comprises a layer comprising polypropylene (PP), polyethylene (PE) and / or polyethylene terephthalate (PET). The respiratory hood 12 can optionally be coated with polypropylene (PP), polyethylene (PE), or polyethylene terephthalate. Such a coating is stabile to gamma or x-ray sterilization of the respiratory hood 12. Gamma or x-ray sterilization is a physical and chemical process that uses gamma rays or x-rays, respectively, to kill bacteria. They are each a form of electromagnetic energy that has low-dose rates and deep penetration.

[0054] In some cases, the permeable media used to make the permeable tunnel cavity 63 comprises a layer comprising polyethylene (PE) and / or polyethylene terephthalate (PET).

[0055] Listing of exemplary Embodiments

[0056] In a first embodiment is provided a respirator system. The respirator system includes a respiratory hood defining an air cavity for a user wearing the respiratory hood, the air cavity having an inlet connectable to a source of breathable air and at least an outlet arranged to deliver breathable air to a face region of the user, wherein the respiratory hood comprises a visor; and a suspension system configured to interface with the user’s head; wherein a permeable media is positioned at a neck seal portion of the respiratory hood to egress air from the air cavity.

[0057] In a second embodiment is provided a respirator system according to the first embodiment, wherein the permeable media is doubled over to form a tunnel cavity.

[0058] In a third embodiment is provided a respirator system according to the second embodiment, further comprising a drawstring positioned through the tunnel cavity. In a fourth embodiment is provided a respirator system according to the second embodiment, further comprising an elastic band positioned in the tunnel cavity.

[0059] In a fifth embodiment is provided a respirator system according to any of the first through fourth embodiments, wherein the air cavity covers substantially the whole of the region of the respiratory hood above the neck of the user and provides support at the perimeter of the respiratory hood for the visor that covers at least the face of the user.

[0060] In a sixth embodiment is provided a respirator system according to any of the first through fifth embodiments, further comprising a shroud configured to be worn by the user under the respiratory hood, wherein the neck seal portion of the respiratory hood is positioned to egress air beneath the shroud.

[0061] In a seventh embodiment is provided a respirator system according to the sixth embodiments, wherein the shroud is a first shroud and the system further comprises a second shroud configured to be worn by the user under the respiratory hood and over the first shroud, wherein the neck seal portion of the respiratory hood is positioned to egress air between the first shroud and the second shroud.

[0062] In an eighth embodiment is provided a respirator system according to any of the first through seventh embodiments, wherein the permeable media comprises a layer comprising polyethylene (PE) and / or polyethylene terephthalate (PET).

[0063] In a ninth embodiment is provided a respirator system according to any of the first through eighth embodiments, wherein the respiratory hood comprises a layer comprising polypropylene (PP), polyethylene (PE) and / or polyethylene terephthalate (PET).

[0064] In a tenth embodiment is provided a respirator system according to any of the first through ninth embodiments, wherein the respiratory hood is coated with polypropylene (PP), polyethylene or polyethylene terephthalate.

[0065] In an eleventh embodiment is provided a respirator system according to any of the first through ninth embodiments, wherein the source of breathable air comprises a breathing tube and wherein the system further comprises a breathing tube cover disposed on the breathing tube, the breathing tube cover comprising a first end and a second end, wherein the first end is elastic and the second end is open.

[0066] Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not limited to the illustrative embodiments set forth herein.

Claims

CLAIMS1. A respirator system comprising: a respiratory hood defining an air cavity for a user wearing the respiratory hood, the air cavity having an inlet connectable to a source of breathable air and at least an outlet arranged to deliver breathable air to a face region of the user, wherein the respiratory hood comprises a visor; and a suspension system configured to interface with the user’s head; wherein a permeable media is positioned at a neck seal portion of the respiratory hood to egress air from the air cavity.

2. The system of claim 1, wherein the permeable media is doubled over to form a tunnel cavity.

3. The system of claim 2, further comprising a drawstring positioned through the tunnel cavity.

4. The system of claim 2, further comprising an elastic band positioned in the tunnel cavity.

5. The system of any of claims 1 to 4, wherein the air cavity covers substantially the whole of the region of the respiratory hood above the neck of the user and provides support at the perimeter of the respiratory hood for the visor that covers at least the face of the user.

6. The system of any of claims 1 to 5, further comprising a shroud configured to be worn by the user under the respiratory hood, wherein the neck seal portion of the respiratory hood is positioned to egress air beneath the shroud.

7. The system of claim 6, wherein the shroud is a first shroud and the system further comprises a second shroud configured to be worn by the user under the respiratory hood and over the first shroud, wherein the neck seal portion of the respiratory hood is positioned to egress air between the first shroud and the second shroud.

8. The system of any of claims 1 to 7, wherein the permeable media comprises a layer comprising polyethylene (PE) and / or polyethylene terephthalate (PET).

9. The system of any of claims 1 to 8, wherein the respiratory hood comprises a layer comprising polypropylene (PP), polyethylene (PE) and / or polyethylene terephthalate (PET).

10. The system of any of claims 1 to 9, wherein the respiratory hood is coated with polypropylene (PP), polyethylene or polyethylene terephthalate.

11. A system of any of claims 1 to 10, wherein the source of breathable air comprises a breathing tube and wherein the system further comprises a breathing tube cover disposed on the breathing tube, the breathing tube cover comprising a first end and a second end, wherein the first end is elastic and the second end is open.

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