Ruggedized powered air purifying respirator

Abstract

A powered air purifying respirator includes: a protective headgear including a face shield; a flexible material configured to seal gaps between an outer frame of the face shield and a head of a user to define a breathing zone; and an airflow system built into the protective headgear, the airflow system including: an air intake filter outside the breathing zone; one or more vents inside the breathing zone; one or more air ducts coupled to the air intake filter and the one or more vents; and a blower coupled to the one or more air ducts, wherein the blower is configured to suction air through the air intake filter to generate filtered air and is further configured to blow the filtered air through the one or more air ducts to direct the filtered air through the one or more vents into the breathing zone.

Description

RUGGEDIZED POWERED AIR PURIFYING RESPIRATOR

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 638,027, filed April 24, 2024, the entire content of which is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates to respiratory protective equipment (RPE).BACKGROUND

[0003] Respiratory aerosols may contain infectious materials (e.g., viral particles) that can expose healthcare, agriculture, health and safety workers, and others to contagion risks. Accordingly, as part of required respiratory protection programs for health and safety, various forms of RPE are used to protect mucus membranes at the eyes, nose, and / or mouth from exposure to infectious aerosols or hazardous particles. For example, healthcare workers may wear face shields and filtering facepiece respirators (FFRs), such as N95 respirators.SUMMARY

[0004] This disclosure describes a powered air purifying respirator (PAPR) configured to provide respiratory and head protection for healthcare workers and other users in environments containing poor air quality due to infectious aerosols or other contaminants. Some PAPR systems are bulky, complicated, difficult to wear, and difficult to remove without exposure to infectious / hazardous particles. The disclosed PAPR solves problems associated with such systems by integrating electronics and airflow systems into a protective headgear that is easily donned and doffed.

[0005] The PAPR may be utilized in a variety of work, clinical, and ambulatory care settings by healthcare workers to provide respiratory protection and prevent the spread of pathogens and exposure to other hazardous materials or particles. The PAPR may also be portable and ruggedized to allow for deployment in non-hospital environments such as outdoor use, field care, military settings, Emergency Medical Services (EMS) transport, triage response, point- of-distribution sites, animal care settings, laboratory, and the like. In some examples, the PAPR provides respiratory protection for users while also preventing the spread of infection from symptomatic or asymptomatic users to others (e.g., from healthcare workers to patients) with built-in source control.

[0006] In an example, the PAPR includes a protective headgear including a face shield. The PAPR further includes a flexible material configured to seal gaps between an outer frame of the face shield and a head of a user to define a breathing zone for the user. The PAPR further includes an airflow system built into the protective headgear. The airflow system includes an air intake filter outside the breathing zone, one or more vents inside the breathing zone, one or more air ducts coupled to the air intake filter and the one or more vents, and a blower coupled to the one or more air ducts. The blower is configured to suction air through the air intake filter to generate filtered air and is further configured to blow the filtered air through the one or more air ducts to direct the filtered air through the one or more vents into the breathing zone.

[0007] The details of one or more examples of this disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of this disclosure will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0008] FIG. l is a perspective view of a PAPR, in accordance with one or more examples of this disclosure.

[0009] FIG. 2 is a side view of the PAPR, in accordance with one or more examples of this disclosure.

[0010] FIG. 3 is a front view of the PAPR, in accordance with one or more examples of this disclosure.

[0011] FIG. 4 is a top view of the PAPR, in accordance with one or more examples of this disclosure.

[0012] FIG. 5 is a perspective view of an airflow system of the PAPR, in accordance with one or more examples of this disclosure.

[0013] FIG. 6 is a block diagram of an example configuration of the airflow system of the PAPR, in accordance with one or more examples of this disclosure.

[0014] FIG. 7 is a perspective view of the PAPR worn by a user, in accordance with one or more examples of this disclosure.

[0015] FIG. 8 is a perspective view of the PAPR worn by the user, illustrating a multisection protective drape of the PAPR, in accordance with one or more examples of this disclosure.

[0016] FIG. 9 is a perspective view of the PAPR worn by the user, illustrating a multisection protective drape of the PAPR, in accordance with one or more examples of this disclosure.

[0017] FIG. 10 is a perspective view of the PAPR worn by the user, illustrating a multisection protective drape of the PAPR, in accordance with one or more examples of this disclosure.

[0018] FIG. 11 is a front view of the PAPR worn by the user, illustrating a multi-section protective drape of the PAPR, in accordance with one or more examples of this disclosure.

[0019] FIG. 12 is a perspective view of the PAPR worn by the user, illustrating a multisection protective drape of the PAPR, in accordance with one or more examples of this disclosure.

[0020] Like reference characters denote like elements throughout the description and figures.DETAILED DESCRIPTION

[0021] To protect themselves from infectious or hazardous particles, healthcare workers or other users may wear various forms of RPE. Face shields and FFR, such as N95 respirators, are types of RPE that may be worn by healthcare workers in clinical and ambulatory care environments. However, extended use of FFRs can be very hard on facial skin, and fogging can be a challenge with face shields. Healthcare workers may use PAPRs as a more comfortable alternative form of RPE. In some examples, a PAPR may provide a continuous flow of filtered air within a hood that fully covers the head of a user.

[0022] PAPRs may offer at least the same protection as FFRs and do not have to be worn tightly over the mouth and nose region of the face, but some PAPRs are noisy, heavy, and cumbersome. Some PAPRs also require extensive training and education to use correctly. PAPRs can also be difficult to difficult to wear, and difficult to remove without exposure to infectious / hazardous particles. Some PAPRs may also create significant waste with disposable hoods and tubing that may be too difficult to clean and reuse, when possible.

[0023] Additionally, some PAPRs only protect the user and do not include any source control to protect others, such as patients or other healthcare workers, from infectious particles that may be present in respiratory aerosol expelled by the user. The COVID-19 pandemic increased awareness of the need for source control when using RPE, e.g., to protect patients from pathogens that could be transmitted by healthcare workers. Source control may be ofincreased importance when dealing with highly infectious pathogens and / or a vulnerable patient population such as elderly or immunocompromised patients. One method of implementing source control is to wear a mask under the PAPR, but this can lead to fogging and user discomfort. Masks also cover facial expressions and may limit communication as a result.

[0024] This disclosure describes a PAPR that solves problems associated with FFRs and other PAPR systems by integrating electronics and airflow systems into a protective headgear that may be donned and doffed easily by the user themselves. Other PAPR systems may require others to help a user don and doff the system, which places the others at risk of exposure particularly when helping the user remove the system. Additionally, any difficulty in donning and doffing the system adds to the amount of time that a user or those helping the user are at risk of exposure to infectious / hazardous materials. The PAPR may be utilized in a variety of clinical and ambulatory care settings by healthcare workers to provide respiratory protection and prevent the spread of pathogens and other hazardous materials. The PAPR may also be portable and ruggedized to allow for deployment in non-hospital environments such as outdoor use, field care, military settings, EMS transport, triage response, point-of-distribution sites, animal care settings, laboratory, and the like. In some examples, the PAPR provides respiratory protection for users while also preventing the spread of infection from symptomatic or asymptomatic users to others (e.g., from healthcare workers to patients) with built-in source control.

[0025] Although this disclosure often refers to healthcare related implementations of the PAPR, the PAPR may be configured to protect users in other settings such as material and chemical manufacturing, production, development and refining, research laboratories handling hazardous materials, or any other scenario involving poor, contaminated, or otherwise unsafe air quality. In some examples, the PAPR’s portable and ruggedized design allows for its deployment in challenging to navigate environments and environments requiring head protection for the user.

[0026] Compared to other PAPR systems, the presently disclosed PAPR may be easier to use and clean when needed rapidly in clinical care because its airflow systems and electronics are all built into a protective headgear and may include or be covered by smooth, easy to wipe surfaces. In some examples, the weight of the PAPR is also lighter than existing PAPRs. All electronics may be integrated into the protective headgear of the PAPR to lower decibel production (i.e., reduce noise) and to facilitate improved cleaning and sanitization. Theprotective headgear may also attach securely to a user’s head in comparison to the hood designs of other PAPR systems that inflate around the user’s head and may be subject to wind resistance, vibrations, and echoes, making it difficult for the user to move around and hear others. The PAPR may also include a large face shield window to make all or most of the user’ s face visible to others, allowing for improved interactions with patients and other healthcare workers by enabling them to see the user’s expressions and, in some examples, even read the user’s lips.

[0027] This disclosure describes a PAPR 100 in the examples discussed below with reference to FIGS. 1-12. Those skilled in the art will appreciate that any of the examples illustrated in FIGS. 1-12 can be modified by changing dimensions or adding / removing non- essential components or fillers. Furthermore, two or more examples (or portions thereof) can be combined to achieve additional examples that are not necessarily shown in one figure. As such, FIGS. 1-12 should not be construed as restrictive of any particular example and are intended instead as visual aids to help describe configurations of certain components that may apply to multiple examples of PAPR 100.

[0028] FIGS. 1-4 are examples of perspective, side, front, and top views of PAPR 100, respectively. As shown in FIG. 1, PAPR 100 includes a protective headgear 102. Protective headgear 102 may be a helmet, hardhat, or any other form of head protection that covers top and side portions of a user’s head. In some examples, protective headgear 102 includes a securable head cover 104 that is configured to be secured to the user’s head. For example, securable head cover 104 may include a curved shell that fits over the user’s head. In some examples, securable head cover 104 includes an inner padding 106, such as helmet padding, that conforms to the user’s head. Inner padding 106 may cushion and protect the user’s head from shock of impact and / or help reduce or dampen vibrations around the user’s head. Securable head cover 104 may also be secured by friction between the user’s head and inner padding 106. Additionally, or alternatively, securable head cover 104 can be secured to the user’s head by a securement device such as an adjustable strap or belt. In some examples, the securement device may include a ratchet or pin-lock suspension for tightening or loosening the securement device.

[0029] Protective headgear 102 may include a face shield 110 that is built into or coupled to protective headgear 102. Face shield 110 includes a see-through panel 112 mounted within or onto an outer frame 114. Panel 112 may be made of transparent glass or plastic, such as polycarbonate, polyethylene terephthalate glycol (PETG), or the like. Panel 112 may also betreated with an anti -fog coating such as acetate. In some examples, face shield 110 is built into protective headgear 102. For example, outer frame 114 may be permanently attached to headgear 102 or part of a same continuous structure that is 3D printed, cast together, fused together after printing or casting, or otherwise manufactured as a single unit. In other examples, face shield 110 is removably attached to headgear 102, e.g., by one or more fasteners, clips, friction-fit couplings, or the like. In some examples, outer frame 114 may also be pivotally coupled to protective headgear 102 so that face shield 110 can be selectively raised into an inactive configuration (off the user’ s face) or lowered into active configuration (over the user’ s face). For example, protective headgear 102 and outer frame 114 of face shield 110 may be coupled together by one or more pivots, e.g., on either side of the outer frame 114. In other examples, face shield 110 is fixed with respect to headgear 102. Some benefits of a fixed configuration include reduced vibrations and less chance of capturing infectious or hazardous material between moveable components.

[0030] In some examples, face shield 110 may be larger than an average user’s face profile. For example, face shield 110 may have a width greater than an average user’s ear-to-ear distance and a length greater than an average user’s forehead-to-chin distance. In some examples, face shield 110 may include panel 112 and outer frame 114 dimensions based on (National Institute for Occupational Safety and Health) NIOSH Anthropometric Data and ISO Digital Headforms, published by The National Personal Protective Technology Laboratory (NPPTL), updated November 20, 2024.

[0031] PAPR 100 may include a flexible material configured to seal gaps between outer frame 114 of face shield 110 and a head of a user to define a breathing zone for the user. For example, in FIG. 7, PAPR 100 includes flexible material 120 coupled to outer frame 114 of face shield 110. Protective headgear 102, face shield 110, and flexible material 120 surround the user’s face to create a breathing zone 121, i.e., a substantially closed environment around the user’s face, in which PAPR 100 is configured to supply a filtered air for the user. In some examples, flexible material 120 is a fluid resistant fabric such as a textile material treated with fluid resistant coating, scuba rubber, biological suit material, thermoplastic polyurethane (TPU), silicone rubber, nylon with durable water repellent (DWR) coating, polyvinyl chloride (PVC) coated fabrics, Gore-Tex®, neoprene, or any other flexible and fluid resistant material. Additional examples of appropriate materials may include, but are not limited to, spunbond- meltblown-spunbond (SMS) polypropylene, a polyethylene-coated nonwoven, a laminated composite incorporating polyethylene or polyurethane film, a spunlace fabric, or a reusablewoven textile such as a polyester-cotton blend treated with a fluid-repellent and / or antimicrobial finish. Flexible material 120 may be removably coupled to outer frame 114 so that flexible material 120 and outer frame 114 can be disassembled for sanitization and reassembled thereafter.

[0032] Referring again to FIG. 1, PAPR 100 further includes an airflow system 122 built into protective headgear 102. For example, components of airflow system 122 may be permanently or removably attached to securable head cover 104 of protective headgear 102. In some examples, one or more components of airflow system 122, such as electronics or air ducts, may be integrated within the structure of securable head cover 104. In other examples, components of airflow system 122 are all mounted onto securable head cover 104. For example, FIG. 2 is a side view of PAPR 100 showing an example configuration of the components of airflow system 122 mounted onto securable head cover 104, wherein the components of airflow system 122 extend from a rear of protective headgear 102 to a front of protective headgear 102, i.e., to face shield 110.

[0033] FIG. 5 is a perspective view of airflow system 122, shown without protective headgear 102. Airflow system 122 may include an air intake filter 124, one or more air ducts 128 (e.g., air inflow duct 128A and air outflow duct 128B) coupled to the air intake filter 124, and a blower 130 coupled to the one or more air ducts 128. Blower 130 may be configured to suction air through the air intake filter 124 to generate filtered air. Blower 130 may be further configured to blow the filtered air through the one or more air ducts 128 to direct the filtered air through one or more vents 126 at a distal end of the one or more air ducts 128, e.g., a distal end of air outflow duct 128B.

[0034] In some examples, air intake filter 124 is located outside the breathing zone 121. For example, in FIG. 2, air intake filter 124 is located at the rear of protective headgear 102. This configuration ensures that airflow system 122 can suction air (i.e., unfiltered air) through air intake filter 124 at a location away from the user’s face, e.g., from behind the user’s head. Air intake filter 124 may be coupled to the one or more air ducts 128 (e.g., to air inflow duct 128A) by a cooperative coupling 125 that allows air intake filter 124 to be removed, e.g., to clean its casing, replace a filter, or replace air intake filter 124 altogether. Cooperative coupling 125 may include, but is not limited to, cooperative threading, a push-to-connect coupling, a camlock, a barbed connector, or a twist lock connector. In some examples, cooperative coupling 125 includes cooperative threading of an M25xl thread, although other thread dimensions may be appropriate. Cooperative coupling 125 may allow for construction ofprintable adapters to accommodate different filter types. Cooperative coupling 125 can also enable air intake filter 124 to be selected from a plurality of different air intake filters, e.g., with varying performance characteristics. For example, lower grade air filters with better flow characteristics may be used in low-risk environments (e.g., to filter out dust or other benign particles) whereas higher grade air filters may be used in environments that pose a greater risk of contamination or harm to the user (e.g., exposure to highly infectious pathogens or other harmful materials). In some examples, air intake filter 124 is an N100, R100, P100 or other high efficiency particulate air (HEP A) filter with splash protection. In some examples, air intake filter may be configured to filter at least 99.97% of airborne particles.

[0035] The one or more vents 126 may be located inside and / or configured to blow air (i.e., filter air) within the breathing zone 121. For example, as shown in FIG. 1, PAPR 100 may include a vent frame member 132 coupled to outer frame 114 of face shield 110. Vent frame member 132 may be coupled to a top frame member 116 of outer frame 114 such that vent frame member 132 is situated between the top frame member 116 of outer frame 114 and securable head cover 104 of protective headgear 102, e.g., as shown in FIG. 4. In some examples, vent frame member 132 occupies an area between securable head cover 104 and outer frame 114. Vent frame member 132 includes one or more openings for the one or more vents 126 so that the one or more vents 126 can blow air into a space between the user’s face and face shield 110, i.e., into the breathing zone 121. As shown in FIG. 7, PAPR 100 may blow filtered air within the breathing zone 121, via the one or more vents 126 (not shown in FIG. 7), along an airflow path 134 extending from a top frame member 116 of outer frame 114 toward a bottom frame member 118 of outer frame 114. In this manner, filtered air is continuously blown across the user’s face going from top to bottom. The direction of airflow path 134 may provide cooling comfort to the user and also ensure that any respiratory aerosols expelled by the user are blown down and away from the user’s field of view.

[0036] In some examples, such as in FIG. 6, airflow system 122 may further include one or more air steering components 127 coupled to the one or more vents 126. The one or more air steering components 127 may control an airflow angle of the filtered air within the breathing zone 121. For example, the one or more air steering components 127 may be configured to tilt airflow path 134 (or paths) of filtered air being blown from the one or more vents 126 within the breathing zone 121. In some examples, the one or more air steering components 127 may include one or more repositionable nozzles, louvered vent covers, baffles, or the like. The one or more air steering components 127 may allow the user to control airflow within the breathingzone 121 so that filtered air is not being blown into the user’s eyes or, more generally, to provide a direction of airflow path 134 that is comfortable to the user.

[0037] The user’s breath and unused filtered air leaves the PAPR through one or more exhaust ports. For example, in FIGS. 2 and 3, PAPR 100 includes an exhaust port 136 adjacent to bottom frame member 118 of outer frame 114 of face shield 110. In some examples, exhaust port 136 is built into a frame member that is coupled to bottom frame member 118 of outer frame 114. In other examples, exhaust port 136 may be defined by one or more openings within flexible material 120. PAPR 100 may also have source control built into the face shield 110 and / or flexible material 120. For example, as shown in FIG. 2, exhaust port 136 may include a source control filter 138. In some examples, source control filter 138 is coupled to exhaust port 136. In other examples, source control filter 138 may simply overlay exhaust port 136. Source control filter 138 may include, but is not limited to, surgical mask material or any other American Society for Testing Materials (ASTM) level 3 filter material. In some examples, source control filter 138 may include a higher or lower grade filter material depending on the application and / or environment in which PAPR 100 is to be deployed.

[0038] Blower 130 is configured to generate airflow within and through airflow system 122. For example, blower 130 is configured to suction air into airflow system 122 via air intake filter 124 to generate filtered air. Blower 130 then blows the filtered air through the one or more air ducts 128 until the filtered air is released through the one or more vents 126 into the breathing zone 121. In some examples, the one or more air ducts 128 include air inflow duct 128 A and air outflow duct 128B. Blower 130 may be coupled between air inflow duct 128 A and air outflow duct 128B such that blower 130 suctions air into the airflow system 122 via air inflow duct 128 A (running between air intake filter 124 and blower 130) and then blows filtered air through air outflow duct 128B to direct the filtered air through the one or more vents 126 into the breathing zone 121.

[0039] In some examples, such as in FIG. 5, blower 130 is coupled to the one or more air ducts 128 (e.g., to air outflow duct 128B) by a cooperative coupling 131 that allows blower 130 to be disconnected from the one or more air ducts 128, e.g., to clean or replace the blower or portions of ductwork. Cooperative coupling 131 may include, but is not limited to, cooperative threading, a push-to-connect coupling, a camlock, a barbed connector, or a twist lock connector. In some examples, cooperative coupling 131 includes cooperative threading of an M25xl thread, although other thread dimensions may be appropriate. In general, cooperative couplings, such as cooperative couplings 125 and 131, may allow components to bedisassembled so that they can be sanitized and then reassembled thereafter. The ability to disassemble various components of airflow system 122 may also provide maintenance and repair options for PAPR 100. Any technique known in the art may be used to sanitize components of PAPR 100. For example, components may be washed thoroughly and / or subjected to heat, chemical agents, and / or radiation (e.g., UV light) to sanitize or decontaminate the components.

[0040] The use of one or more air ducts 128 to connect air intake filter 124, blower 130, and vents 126 may provide certain advantages for air flow and may reduce noise within the system because of less vibrations as a result of the spacing between these components of airflow system 122. The integration of airflow system 122 components into the protective headgear 102 and optional sound dampening features (e.g., inner padding 106) may also serve to reduce noise. In some examples, PAPR 100 may be configured to generate an operational sound output below 50 decibels (dB); although higher noise output may be appropriate in certain examples such as in environments wherein higher fan speeds are used. The spacing between air intake filter 124 and blower 130 can also help prevent blower 130 and other electronics of airflow system 122 from overheating.

[0041] Blower 130 may include an electric motor and fan configured to move air at a rate that complies with PAPR specifications which may vary depending on the setting. For example, blower 130 may be configured to move air at a rate of at least 170 liters per minute (LPM) or 6 cubic feet per minute (CFM) to comply with NIOSH performance specifications for loosefitting hoods and helmets, as provided in Title 42, Code of Federal Regulations, Part 84. In some examples, blower 130 may be configured to move air at a rate of up to 250 LPM. The foregoing ranges are provided as examples, and it shall be understood that other operational ranges may be appropriate in certain settings.

[0042] As shown in the example configuration of FIG. 6, blower 130 may be powered by a battery 140 and controlled by control circuitry 142. In some examples, battery 140 is a rechargeable battery. For example, in FIG. 1, battery 140 is a rechargeable and swappable battery pack that can be connected and disconnected from a battery dock, e.g., like a swappable battery of a leaf blower or other power tool. In some examples, such as in FIG. 4, battery 140 may be configured to dock in between the one or more air ducts 128 (e.g., between branches of air outflow duct 128B). This configuration allows for a low profile and good weight distribution because blower 130 and battery 140 are aligned and centered on top of securable head cover 104 of protective headgear 102.

[0043] In some examples, such as in FIG. 7, protective headgear 102 may further include an outer casing 108 that attaches to securable head cover 104 (not shown in FIG. 7) and covers one or more components of airflow system 122. For example, outer casing 108 may cover at least a portion of the one or more air ducts 128 (not shown in FIG. 7) and blower 130 (not shown in FIG. 7) that are disposed between securable head cover 104 and outer casing 108. Outer casing 108 may have a smooth surface that is easy to disinfect and may serve to protect covered components of airflow system 122 from contaminants. Outer casing 108 can be made of a hard material (e.g., fiberglass, carbon fiber, composite material, plastic, Kevlar, or other helmet or hardhat materials) that may also protect covered components of airflow system 122 from impact of falling objects or debris. In some examples, PAPR 100 also includes a protective casing or cover (not shown) for battery 140. PAPR 100 can also include a light source (not shown) above or at the top of face shield 110 to improve user visibility. In some examples, the light source is embedded within outer casing 108 or outer frame 114 of face shield 110.

[0044] Control circuitry 142 may be mounted onto and / or at least partially embedded within securable head cover 104. Additionally, or alternatively, at least a portion of the control circuitry 142 may be mounted onto or built into blower 130. As shown in FIG. 6, control circuitry 142 may be coupled to battery 140 and blower 130. Control circuitry 142 may be configured to control a power signal from battery 140 to blower 130. In some examples, control circuitry 142 includes a switch (e.g., an on / off switch, button, toggle, or the like) that is configured to selectively power blower 130 on and off. In some examples, control circuitry 142 additionally or alternatively includes a variable control switch (e.g., a rheostat, potentiometer, or multi-step power switch or dial) configured to control a power level of blower 130, e.g., to increase or decrease a fan speed of blower 130. In some examples, the variable control switch is also the on / off switch, wherein the lowest power setting is a powered off state of blower 130. The ability to control the fan speed of blower 130 can provide several advantages. For example, the user may increase the fan speed to provide a higher rate of airflow for comfort, such as when the user is overheated or finding difficulty breathing. In some examples, blower 130 may also include a cooling element to support temperature control. In another example, the user may decrease the fan speed if the user can tolerate a lower rate of airflow in order to prolong battery life.

[0045] In some examples, control circuitry 142 may include processing circuitry (e.g., a processor or controller) that executes program instructions from memory to control the powersetting of blower 130 based on user inputs or one or more sensors 144. For example, processing circuitry may be configured to execute program instructions from the memory that cause the processing circuitry to selectively power blower 130 on and off and control a power level of blower 130 based on a user input entered through a user interface (e.g., switch, button, dial, touchpad, touchscreen, or the like). In some examples, the processing circuitry is configured to selectively power blower 130 on and off and control the power level of blower 130 based on information received from the one or more sensors 144. For example, the one or more sensors 144 may include one or more of a temperature sensor, an air quality sensor, a heart rate sensor, a body temperature sensor, a battery sensor, or the like. In one example, processing circuitry may increase the fan speed of blower 130 based on information received from the one or more sensors 144 that indicates the user may be subject to excess heat or difficult breathing conditions. In another example, processing circuitry may decrease the fan speed of blower 130 based on information received from the one or more sensors 144 that indicates low battery life and / or conditions at which the user can tolerate a lower fan speed.

[0046] In some examples, flexible material 120 is configured to be coupled to a full body personal protective equipment (PPE) suit (interface of one PPE element with another). For example, flexible material 120 may include one or more fasteners (e.g., buttons, buttonholes, snap fasteners, clasps, zipper elements, VELCRO elements, tabs, etc.) that are configured to secure a lower edge of flexible material 120 to a collar of a full body PPE suit or simply support safe doffing. Alternatively, flexible material 120 may be coupled to the full body PPE suit by simply nesting the lower edge of the neck shroud within the collar and hood of the full body PPE suit.

[0047] As shown in FIG. 7, PAPR 100 may further include a protective drape 146 configured to extend from face shield 110 across at least a portion of a body of the user. Protective drape 146 may provide a protective interface between faces shield 110 (or flexible material 120) and a full body PPE suit or gown worn by the user. For example, protective drape 146 may drape down the user’s body from a lower edge of outer frame 114 of face shield 110 and can be tucked into or drape over a portion of a PPE suit or gown that is worn by the user. In some examples, protective drape 146 is attached to bottom frame member 118 of outer frame 114 of face shield 110 by one or more fasteners or a coupling interface, such as the coupling interfaces described below with reference to FIGS. 8-10.

[0048] Protective drape 146 may be made from a fluid resistant fabric such as a textile material treated with fluid resistant coating, scuba rubber, biological suit material, TPU,silicone rubber, nylon with DWR coating, PVC coated fabrics, Gore-Tex®, neoprene, or any other flexible and fluid resistant material. Additional examples of appropriate materials may include, but are not limited to, SMS polypropylene, a polyethylene-coated nonwoven, a laminated composite incorporating polyethylene or polyurethane film, a spunlace fabric, or a reusable woven textile such as a polyester-cotton blend treated with a fluid-repellent and / or antimicrobial finish.

[0049] In some examples, protective drape 146 includes a first section of material 148 fastened to face shield 110 and a second section of material 150 fastened to the first section of material 148. The first section of material 148 may be shorter than the second section of material 150 and may act as an intermediate layer between the second section of material 150 and face shield 110 to allow for easy removal of protective drape 146 during the doffing process. As shown in FIG. 8, the second section of material 150 may be fastened to the first section of material 148 by an adhesive layer 152 so that the second section of material 150 is peelable from the first section of material 148. As a result, the user can peel away the second section of material 150 during the doffing process. Then, the first section of material 148 can be removed with the rest of PAPR 100 when the user takes off headgear 102. For example, the first section of material 148 can be pulled over the user’s head.

[0050] The first section of material 148 may be fastened to the first shield by a mechanical fastening interface, such as a zipper 154 (e.g., see FIGS. 8 and 9), a plurality of buttons, a hook and loop system (e.g., VELCRO), or any other type of fastener that secures the first section of material to face shield 110. In some examples, such as in FIG. 10, the mechanical fastening interface includes a hollow channel 156 configured to receive a reinforced edge 158 of the first section of material 148. For example, the reinforced edge 158 may be formed by thicker (additional layers) of the first section of material 148 or by an embedded or edge-mounted wire or other reinforcement structure.

[0051] Although FIGS. 7-9 show examples of protective drape 146 wherein the first section of material 148 overlays the second section of material 150, in other examples, the first section of material 148 may be at least partially covered by the second section of material 150, e.g., as shown in FIGS. 11 and 12. One advantage of the configuration in FIGS. 11 and 12, wherein the second section of material 150 overlays the first section of material 148, is that the second section of material 150 can protect the first section of material 148 from contamination. As a result, the user may be at less risk of coming into contact with a contaminated surface after thesecond section of material 150 is peeled away from the first section of material 148 during the doffing process.

[0052] Any of the systems or devices described herein may be combined. Additionally, portions of systems or devices described herein may be removed, modified, replaced with functional equivalents, or combined with portions of other systems or devices described herein.

[0053] This disclosure includes the following non-limiting examples.

[0054] Example 1. A PAPR including: a protective headgear including a face shield; a flexible material configured to seal gaps between an outer frame of the face shield and a head of a user to define a breathing zone for the user; and an airflow system built into the protective headgear, the airflow system including: an air intake filter outside the breathing zone; one or more vents inside the breathing zone; one or more air ducts coupled to the air intake filter and the one or more vents; and a blower coupled to the one or more air ducts, wherein the blower is configured to suction air through the air intake filter to generate filtered air and is further configured to blow the filtered air through the one or more air ducts to direct the filtered air through the one or more vents into the breathing zone.

[0055] Example 2. The PAPR of example 1, wherein the protective headgear is a helmet or a hardhat.

[0056] Example 3. The PAPR of any of examples 1 and 2, wherein the protective headgear includes at least one of an inner padding or a securement device.

[0057] Example 4. The PAPR of any of examples 1-3, wherein the protective headgear includes a securable head cover and an outer casing, wherein the one or more air ducts and the blower are disposed between the securable head cover and the outer casing.

[0058] Example 5. The PAPR of any of examples 1-4, wherein the flexible material is a fluid resistant material.

[0059] Example 6. The PAPR of any of examples 1-5, wherein the flexible material is coupled to the outer frame of the face shield.

[0060] Example 7. The PAPR of any of examples 1-6, wherein the one or more air ducts include an air inflow duct and an air outflow duct.

[0061] Example 8. The PAPR of example 7, wherein the blower is coupled to the one or more air ducts, in between the air inflow duct and the air outflow duct.

[0062] Example 9. The PAPR of any of examples 7 and 8, wherein the air intake filter is coupled to the air inflow duct.

[0063] Example 10. The PAPR of any of examples 1-9, further including a vent frame member coupled to the outer frame of the face shield, wherein the vent frame member includes one or more openings for the one or more vents.

[0064] Example 11. The PAPR of any of examples 1-10, wherein the one or more vents are configured to direct the filtered air along an airflow path extending from a top of the outer frame of the face shield toward a bottom of the outer frame of the face shield.

[0065] Example 12. The PAPR of any of examples 1-11, further including one or more air steering components coupled to the one or more vents to control an airflow angle of the filtered air within the breathing zone.

[0066] Example 13. The PAPR of any of examples 1-12, further including an exhaust port adjacent to a bottom of the outer frame of the face shield.

[0067] Example 14. The PAPR of example 13, further including a source control filter at the exhaust port.

[0068] Example 15. The PAPR of any of examples 1-14, further including a rechargeable battery configured to power the blower and control circuitry configured to control the power from the rechargeable battery to the blower.

[0069] Example 16. The PAPR of example 15, wherein the rechargeable battery is a swappable battery pack.

[0070] Example 17. The PAPR of any of examples 15 and 16, wherein the control circuitry includes a switch configured to selectively power the blower on and off.

[0071] Example 18. The PAPR of any of examples 15-17, wherein the control circuitry includes a variable control switch configured to selectively power the blower on and off and further configured to control a power level of the blower.

[0072] Example 19. The PAPR of any of examples 15-18, wherein the control circuitry includes processing circuitry and memory, wherein the processing circuitry is configured to execute program instructions from the memory that cause the processing circuitry to selectively power the blower on and off and control a power level of the blower.

[0073] Example 20. The PAPR of example 19, further including one or more sensors, wherein the processing circuitry is configured to selectively power the blower on and off and control the power level of the blower based on information received from the one or more sensors.

[0074] Example 21. The PAPR of any of examples 1-20, further including a protective drape configured to extend from the face shield across at least a portion of a body of the user.

[0075] Example 22. The PAPR of example 21, wherein the protective drape includes a first section of material fastened to the face shield and a second section of material fastened to the first section of material.

[0076] Example 23. The PAPR of example 22, wherein the second section of material is fastened to the first section of material by an adhesive layer so that the second section of material is peelable from the first section of material.

[0077] Example 24. The PAPR of any of examples 22 and 23, wherein the first section of material is fastened to the face shield by a mechanical fastening interface.

[0078] Example 25. The PAPR of example 24, wherein the mechanical fastening interface includes a hollow channel configured to receive a reinforced edge of the first section of material.

[0079] Example 26. The PAPR of example 24, wherein the mechanical fastening interface includes at least one of a zipper, a plurality of buttons, or a hook and loop system.

[0080] Various examples have been described. These and other examples are within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1. A powered air purifying respirator (PAPR) comprising: a protective headgear including a face shield; a flexible material configured to seal gaps between an outer frame of the face shield and a head of a user to define a breathing zone for the user for the user; and an airflow system built into the protective headgear, the airflow system comprising: an air intake filter outside the breathing zone; one or more vents inside the breathing zone; one or more air ducts coupled to the air intake filter and the one or more vents; and a blower coupled to the one or more air ducts, wherein the blower is configured to suction air through the air intake filter to generate filtered air and is further configured to blow the filtered air through the one or more air ducts to direct the filtered air through the one or more vents into the breathing zone.

2. The PAPR of claim 1, wherein the protective headgear is a helmet or a hardhat.

3. The PAPR of claim 1, wherein the protective headgear includes at least one of an inner padding or a securement device.

4. The PAPR of claim 1, wherein the protective headgear includes a securable head cover and an outer casing, wherein the one or more air ducts and the blower are disposed between the securable head cover and the outer casing.

5. The PAPR of claim 1, wherein the flexible material comprises a fluid resistant material.

6. The PAPR of claim 1, wherein the flexible material is coupled to the outer frame of the face shield.

7. The PAPR of claim 1, wherein the one or more air ducts comprise an air inflow duct and an air outflow duct.

8. The PAPR of claim 7, wherein the blower is coupled to the one or more air ducts, in between the air inflow duct and the air outflow duct.

9. The PAPR of claim 7, wherein the air intake filter is coupled to the air inflow duct.

10. The PAPR of claim 1, further comprising a vent frame member coupled to the outer frame of the face shield, wherein the vent frame member includes one or more openings for the one or more vents.

11. The PAPR of claim 1 , wherein the one or more vents are configured to direct the filtered air along an airflow path extending from a top of the outer frame of the face shield toward a bottom of the outer frame of the face shield.

12. The PAPR of claim 1, further comprising one or more air steering components coupled to the one or more vents to control an airflow angle of the filtered air within the breathing zone.

13. The PAPR of claim 1, further comprising an exhaust port adjacent to a bottom of the outer frame of the face shield.

14. The PAPR of claim 13, further comprising a source control filter at the exhaust port.

15. The PAPR of claim 1, further comprising: a rechargeable battery configured to power the blower; and control circuitry configured to control the power from the rechargeable battery to the blower.

16. The PAPR of claim 15, wherein the rechargeable battery comprises a swappable battery pack.

17. The PAPR of claim 15, wherein the control circuitry comprises a switch configured to selectively power the blower on and off.

18. The PAPR of claim 15, wherein the control circuitry comprises a variable control switch configured to selectively power the blower on and off and further configured to control a power level of the blower.

19. The PAPR of claim 15, wherein the control circuitry comprises processing circuitry and memory, wherein the processing circuitry is configured to execute program instructions from the memory that cause the processing circuitry to selectively power the blower on and off and control a power level of the blower.

20. The PAPR of claim 19, further comprising one or more sensors, wherein the processing circuitry is configured to selectively power the blower on and off and control the power level of the blower based on information received from the one or more sensors.

21. The PAPR of claim 1, further comprising a protective drape configured to extend from the face shield across at least a portion of a body of the user.

22. The PAPR of claim 21, wherein the protective drape comprises a first section of material fastened to the face shield and a second section of material fastened to the first section of material.

23. The PAPR of claim 22, wherein the second section of material is fastened to the first section of material by an adhesive layer so that the second section of material is peelable from the first section of material.

24. The PAPR of claim 22, wherein the first section of material is fastened to the face shield by a mechanical fastening interface.

25. The PAPR of claim 24, wherein the mechanical fastening interface comprises a hollow channel configured to receive a reinforced edge of the first section of material.

26. The PAPR of claim 24, wherein the mechanical fastening interface comprises at least one of a zipper, a plurality of buttons, or a hook and loop system.

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