Personal protective equipment, methods and systems of use thereof

Abstract

An RPD fitting system configured to personalize respirator fit by generating actionable customization instructions. The system includes a respiratory device identifier that recognizes a specific respirator, and a user information retriever that obtains a user indication, such as a facial feature indication. A fit analyzer correlates the identified respirator with the retrieved user fit indication to determine a customization for the respirator and generates an instruction that, when implemented, changes a physical dimension of a respirator feature to improve fit (e.g., altering a face-seal-related dimension). A communication component delivers the customization instruction to the user for execution. By linking respirator identification with user-specific facial data and producing dimension-changing guidance, the system enables on-demand, user-tailored adjustments that enhance sealing performance and comfort across diverse respirator models and user anatomies.

Description

PERSONAL PROTECTIVE EQUIPMENT, METHODSAND SYSTEMS OF USE THEREOFBACKGROUND

[0001] In some environments, a worker may be required to wear one or more articles of personal protective equipment (PPE) while performing a certain job function, working in a specific work environment, or the like. For example, a worker may be required to wear at least one of respiratory-protection equipment, protective eyewear, protective headwear, hearing-protection devices, protective shoes, protective gloves, protective clothing, or any other article of PPE.SUMMARY

[0002] The disclosure describes devices, systems, and techniques relating to personal protective equipment (PPE) fit testing system.

[0003] A respiratory protection device (RPD) is presented that includes a respirator body configured to cover a face of a wearer. The RPD also includes a customizable face seal coupled to the perimeter of the respirator body. The face seal comprises an adjustment feature. Actuation of the adjustment feature adjusts an effective contact area of the customizable face seal with the face of the wearer.

[0004] In one aspect, a respiratory protection device is provided that comprises a respirator body configured to cover a face of a wearer and a customizable face seal coupled to a perimeter of the respirator body, wherein the face seal comprises an adjustment feature and wherein actuation of the adjustment feature adjusts an effective contact area of the customizable face seal with the face of the wearer.

[0005] In another aspect, a respiratory protection device is provided that comprises a respirator body configured to cover a nose and a mouth of a user and a strap connected to the respirator body, the strap configured to, with the respirator body, encircle a head of the user, wherein the strap comprises an adjustment mechanism for altering a length of the strap and a tension indicator configured to provide an indication of an amount of extension of the strap.

[0006] In a further aspect, a method for adjusting the fit of a respiratory protection device is provided, the method comprising receiving an indication of a type of the respiratory protection device using an indication receiver, retrieving, based on the type of the respiratory protection device, a customization option for the respiratory protection device, analyzing a scan of a face of a user of the respiratory protection device, determining a customization for the user based on the scan of the face and the retrieved customization option, and providing an instruction for the user for implementing the customization.

[0007] In yet another aspect, a respiratory protection device fitting system is provided comprising a respiratory device identifier configured to identify a respirator and a user information retriever configured to retrieve a user indication, and further comprising a fit analyzer configured to retrieve a respirator indication based on the identified respirator, to retrieve a user fit indication based on a user facial feature indication, and to generate a respiratory protection device customization instruction for the respirator,wherein the customization, when implemented, changes a dimension of a respirator feature, and a communication component configured to communicate the customization instruction to a user.

[0008] In a still further aspect, a method of generating a fit test result for a respiratory protection device is provided comprising receiving a first scan of a user from a first scanning device, the first scan comprising the user without the respiratory protection device, identifying a plurality of landmarks on the user based on the first scan, calculating a plurality of landmark measurements for the user based on the scan, receiving a second scan of the user from a second scanning device, the second scan comprising the user wearing the respiratory protection device, identifying a fit inconsistency for the user, generating, using a fit test results generator, a fit instruction for the user, and communicating the fit instruction for the user.

[0009] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1 A is a view of a respirator.

[0011] FIGS. IB and 1C illustrate respiratory protection devices (RPDs) worn by users in which embodiments of the present invention may be useful.

[0012] FIG. 2A is a schematic representation showing shirred filter media, which may be used in embodiments herein.

[0013] FIG. 2B is a schematic representation of a cross section of the shirred filter media, showing its construction.

[0014] FIG.2C is a schematic representation of making a shirred filter media according to one embodiment of the present disclosure.

[0015] FIGS. 3A-3E-3 illustrate RPDs with customizable face seals in accordance with embodiments herein.

[0016] FIG. 4 illustrates a method of fitting an RPD in accordance with embodiments herein.

[0017] FIGS. 5A-5D illustrate an RPD with adjustable straps in accordance with embodiments herein.

[0018] FIG. 6 illustrates a method of fitting an RPD in accordance with embodiments herein.

[0019] FIG. 7 illustrates an RPD with a wrinkled-media based harness in accordance with embodiments herein.

[0020] FIG. 8 illustrates an RPD evaluation system in accordance with embodiments herein.

[0021] FIGS. 9A-9G-3 illustrate an example walkthrough for a user customizing an RPD in accordance with embodiments herein.

[0022] FIG. 10 is a block diagram of a PPE fit test system architecture.

[0023] FIGS. 11-13 illustrate computing devices that may be used in accordance with embodiments herein.DETAILED DESCRIPTION

[0024] The Occupational Safety and Health Administration (OSHA) in the United States mandates thatworkers be protected from respiratory hazards, which necessitates the use of personal protective equipment (PPE) such as respirators. Respirators are designed to form a tight-fitting seal around the face, ensuring that air is filtered before being inhaled by the worker. To confirm the suitability of a respirator for a worker's facial features, fit testing is required. However, the current fit testing methods, including qualitative fit test (QLFT) and quantitative fittest (QNFT), are time-consuming, costly, and result in the wastage of respirators as they rely on trial and error. These shortcomings lead to significant inconvenience and expense for both workers and employers. Moreover, fit testing is not always available or feasible in all work settings, and there is no provision for consumer fit testing.

[0025] To enable reliable, reproducible, and model-specific adaptation of a respirator’s physical features to an individual user’s facial morphology so as to improve sealing performance and comfort, while reducing reliance on trial -and-error sizing and skilled operator judgment. Specifically, there is a need to determine and communicate user-specific dimensional changes to one or more respirator features (e.g., a face seal aperture) based on measurable user indications and the identified respirator, such that the implemented changes achieve an adequate fit across diverse respirator models and user anatomies.

[0026] Aspect of the present disclosure can relate to a respirator fitting system that deterministically converts user-specific facial information into model-specific, dimension-changing customization instructions for a given respirator. A respiratory device identifier first recognizes the respirator (e.g., model / version), enabling retrieval of associated geometric descriptors and modifiable feature constraints. A user information retriever acquires a user indication, including or derived from facial feature indications, which the fit analyzer normalizes and interprets as a user fit indication. The fit analyzer then correlates the respirator indication with the user fit indication to compute one or more dimensional deltas for a respirator feature (for example, a change to the area, perimeter, or contour of a face-seal region), subject to modelspecific safety and manufacturability constraints. The system can output an RPD customization instruction that encodes these dimensional changes in implementable form (e.g., a target size, contour, or boundary path), and a communication component delivers the instruction to the user for execution. This architecture provides a reproducible, data-driven pathway from identified respirator and quantified facial characteristics to concrete, dimensional adjustments that improve fit. As used herein, “RPD customization instruction” means a system-generated directive, specific to a respirator model and wearer, that specifies how to implement a fit-improving, dimension-changing modification to a respirator feature (e.g., what change, where, and by how much) so that, when followed, the respirator is altered accordingly.

[0027] As used herein, “respirator indication” means the information that identifies the specific respirator presented to the system (e.g., make, product line, model, size, version / revision), obtained via user input, barcode / RFID / NFC, or image-based recognition, together with the linked model-specific specifications used for fit analysis and customization (for example, feature geometry, allowable modification constraints, strap type and force-extension data, baseline tension-indicator patterns, and certification rating such as N95 or PlOO).

[0028] The term “face mask” generally refers to a face covering that inhibits droplets from the wearer from spreading, e.g. from a cough or a sneeze. However, face masks often provide little or no protection against droplets from another individual.

[0029] The National Institute for Occupational Safety and Health (NIOSH) approves respirators having a filtration efficacy of at least 95%, e.g. at least 95% of particulates are removed from the air by the filter material. NIOSH, and the Center for Disease Control (CDC) note that respirators provide more protection than face masks (e.g. barrier face coverings, disposable face masks and cloth masks). Other international bodies also provide certification based on filtration efficacy, such as the KN95 or KN99 standard.

[0030] As used herein, the term “respirator” refers to a close-fitting facial covering device that filters inhaled and exhaled air of particles and droplets at a filtration efficacy of at least 95%, in accordance with the NIOSH N95® standard.

[0031] Filtering facepiece respirators (FFRs), in contrast, are designed to seal to a user’s face, such that inhaled air is forced through one or more filter layers, such that most droplets, microbes, and particulates are removed from inhaled air before it reaches a wearer. Additionally, some FFRs include charged fibers that attract microbes or particulates, providing increased protection.

[0032] F(FFRs are sometimes referred to as disposable respirators (DRs). When worn properly, FFRs are designed to protect the wearer by removing harmful particles from inhaled air. FFRs are regulated by the National Institute for Occupational Safety and Health (NIOSH). To provide the required level of protection, an FFR must seal to the wearer’s face, preventing gaps between the respirator and the wearer’s skin since such gaps can allow contaminated air to leak into the breathing zone of the wearer. Therefore, tight fit of the FFR to the face of the wearer is essential.

[0033] Described herein are articles that are formed of shirred media, interchangeably referred to as “wrinkled media” throughout.

[0034] Respiratory protection devices are mass produced with the goal of fitting many different facial structures, including male and female, high or low cheekbones, prominent jaws, etc. Additionally, respiratory protection devices are often worn during activity, such that the wearer may have different facial expressions during use, may walk or run, may sweat or laugh. Additionally, different types and different models of respiratory protection device may be worn at different facial positions for the same user, depending on usage or activity.

[0035] Ideally, when worn, a respiratory protection device should fit the contour of the face of a wearer to form good sealing between the respirator and the face of the wearer. However, the contour of the face of the wearer is not the same between individuals, and there can be large differences from individual to individual. The contour of the nose is complex and fluctuates; it is often difficult to form a good seal, and a gap is often present between the respiratory protection device and the nose area of the wearer, resulting in a poor sealing effect. As a result, dust, mist, bacteria, virus, or fungi in an environment where the wearer is located will be in contact with the wearer through the gap and is inhaled by the wearer, thus affecting the protective effect of the respirator. Additionally, the exhaled breath of the wearer will also be discharged upwards through this gap. For the case where the wearer wears glasses, if the temperature in the respiratoris higher than the ambient temperature, the exhaled breath will cause fogging and affect the wearing experience of the wearer.

[0036] Therefore, in order to improve the protective effect of a respiratory protection device and improve the wearing experience, it is expected that the respiratory protection device can fit the contour of the face of the wearer and achieve good sealing between the respiratory protection device and the face of the wearer. In some RPDs, a metal or plastic nose strip with a memory effect is used to hold the RPD against a face of an individual. However, other sealing or seal -improving options may be used, including a shaped nose foam as described in PCT Publication WO 2022 / 235472, published on November 10, 2022.

[0037] Described in embodiments herein are articles of PPE that have a fit adjustable component. In some embodiments, the fit adjustable component includes an irreversible element, such as a portion that can be cut or tom away from the body of the PPE. In some embodiments, the fit adjustable component includes a reversible component.

[0038] In some embodiments herein, articles of PPE are designed to be used with a computer-implemented fit application which may assist a user of the article of PPE in finding a suitable and comfortable fit.

[0039] As described herein, in some embodiments a computer-implemented fit application uses camera vision to scan a user's face and provide recommendations for the optimal respirator model, respirator configuration, and / or headband adjustment. The computer-implemented application may include a fit model that is trained on a database of images related to PPE fit - users wearing respirators and corresponding fit information - qualitative and / or quantitative fit information.

[0040] One area of fit concern for many users is having a respirator tight against their face. A number of users may believe that a respirator headband needs to be tighter for a good fit than it actually needs to be.

[0041] In some embodiments, based on known headband force-extension relationships and novel headband surface patterns, a computer-implemented fit model may measure a headband extension when a respirator is donned. The model may calculate the forces exerted by the headbands on the user's face and provides customized recommendations for both the type and model of respirator and the headband adjustment. For example, a user may receive the instruction that they can loosen a headband a certain distance, which may increase comfort while wearing the respirator.

[0042] Another area of concern for designers of respirators is the ability to fit a given respirator model to a greater number of individuals. Humans have a wide range of facial dimensions and differences in facial features. Additionally, some individuals may have facial incongruities - scars, bums, etc. Embodiments herein include respirators with a fit adjustment component that allows for custom sizing of the face seal to fit the user. The respirator includes a wrinkled media seal with multiple size perforations, which the user can modify for an optimum fit. The computer-implemented application may provide the user with instructions to remove seal material along the designated perforation based on a facial scan so that the respirator better fits the user. This may reduce the time, errors, and number of respirators used in the typical fit testing process. It may also result in improved respirator wearing compliance.

[0043] In some embodiments herein, respirators include different sizes and shapes of face seals to accommodate various facial features, including those of children or individuals with unique facialcharacteristics like bums or scars. Prototypes with different features, such as adjustable ear loops and nose pads, have been tested and shown to significantly reduce face seal leakage.

[0044] U.S. Provisional Patent Application having Ser. No. 63 / 584916, filed September 25, 2023 describes an example digital fit testing application which may be useful in some embodiments herein. However, it is expressly contemplated that articles of PPE described herein may be useful with other systems.

[0045] FIG. 1 is a view of a respirator. Respirator 10 is an earloop respirator. In the example shown in the drawing, respirator 10 is a foldable earloop respirator. However, the present invention is not limited thereto, and may also be applied to non-foldable or non-earloop respirators as well as to other RPDs more broadly. In the manufacturing process of the first respirator 10, a formable nose piece (often metal, however other suitable materials are envisioned) is attached to an inner or outer side of a respirator main body 11, within area 12. When the first respirator 10 is worn, a lanyard 13 is hung on the left and right ears of the wearer, respectively.

[0046] It is intended that a user adjust respirator 10 so that the nose of the wearer is accommodated in by adjusting the formable nose piece such that area 12, and the exterior edge 15 conform to the contour of the face of the wearer to closely fit the periphery of the nose of the wearer, thus reducing or even eliminating the gap between the respirator and the nose of the wearer. A good seal between respirator 10 and the face of the wearer is important for safety concerns.

[0047] Earloops 13, or another tension device such as a headband, pull RPD 10 toward the face of a user, causing a seal to form on a face contacting portion of the RPD. A seal may not necessarily form along edges 15.

[0048] FIGS. IB and 1C illustrate a respiratory protection device worn by a user in which embodiments of the present invention may be useful. As illustrated in FIGS IB and 1C, respiratory protection devices 100 and 150 can be secured over a user’s face using a variety of methods other than the lanyard illustrated in FIG. 1A.

[0049] Respiratory protection devices 100 and 150 are intended to form a seal along the edges of the RPD, where the face-contacting side contacts the face. A user can adjust a nose clip 110, 160 to improve the fit of respiratory protection devices 100, 150, particularly along the user’s nose, as indicated by areas 120, 170. A user can adjust how tightly a respirator is pulled against their face using headband 130, 180. Not shown in FIGS. 1A-1C, in some embodiments, is a face seal that may directly contact the skin of a user’s face under respirator 100, 150.Wrinkled Media

[0050] Some embodiments herein incorporate a type of functional media laminate (referred to as Wrinkled Media hereafter) with optional reticulated support as a component forming a respirator body, headband strap, and / or another component. Wrinkled Media is described in greater detail with respect to function in the Examples section of PCT Publication 2024 / 137158, published June 27, 2024, which is incorporated by reference herein. FIGS. 2A-2C illustrate an example of wrinkled media and a method of forming the same. However, it is expressly contemplated that other methods may be used to form wrinkled media used inembodiments herein.

[0051] Wrinkled media differs from flat sheet and pleated pack commonly used in respirators in several ways. It provides larger surface area with compact profde through the wrinkled surface. The elastic construction enables stretching capabilities, potentially allowing for better fitting or more comfortable and conformable respirator designs. And some embodiments herein include a reticulated open mesh (referred to as “skip slit” hereafter (For example, as described in PCT Publication WO 2018 / 090280 Al) shell or an elastic netting, which provides support to wrinkled media with resilience to stretch.

[0052] Respirators in embodiments herein, in addition to having a unique appearance, exhibits lower breathing resistance and stretchy functionality while maintaining good fit. With proper respirator design such as multi-panel or support shell components, respirators described herein exhibit low pressure drop with good stretchability. In some embodiments, the respirator can also be folded to flat.

[0053] Embodiments herein contrast with previous work that either used plastic structures to support extra filter media to give it stretchability (but made them bulky and not foldable) or using corrugated media to help decrease breathing resistance (but not stretchable or foldable).

[0054] Shown in FIG. 2A is top view of an exemplary embodiment of a shirred filter media. Shirred filter media 210 comprises a plurality of elastic filaments that are spaced apart. The plurality of elastic filaments are sandwiched between two non-woven porous fibrous webs. During fabrication of the shirred filter media (herein referred to as “wrinkled media”), the elastic filaments are pulled under tension, such that when the tension is released, the non-woven porous fibrous webs become puckered.

[0055] Shown in FIG. 2B is a side view of filter media 220 showing a first non-woven porous fibrous web 24 and a second non-woven porous fibrous web 226, with elastic filament 222 positioned therebetween. FIG. 2B shows that first non-woven porous fibrous web 24 is in direct contact with second non-woven porous fibrous web 226. Based on the resulting articles, it is believed that when adhesive is used, the adhesive bonds the two non-woven porous fibrous webs together with the filaments therebetween. It is assumed that the bonding of the first and second non-woven porous fibrous webs is discontinuous and that the non-woven porous fibrous web(s) may not be bonded (for example, adhesively bonded) to the filament along the full length of the filament.Elastic filaments for use in Wrinkled Media

[0056] The filaments used in some embodiments herein include a polymer and are elastic in nature, meaning that the filament is capable of recovering or at least partially recovering in length following stretching. Exemplary types of polymeric materials that may be used for filaments of the present application include: natural rubber, polyether-polyurethanes, polyamides, polyisoprenes, copolymers of isoprene and neoprene, polymers of 2-chloro-l, 3-butadiene, polyether-polyurea copolymer (e.g., Lycra), polyurethane (e.g., spandex). Other examples include Kraton™ copolymers. Those are elastomeric tri-block polymers comprising high Tg end blocks made of polystyrene and low Tg center block made of one or more isoprene, butadiene, and the like.

[0057] In one embodiment, the filaments have an effective diameter of at least 1, 5, 10, or even 20micrometers and at most 25, 50, 100 micrometers. In one embodiment, the filaments have a denier of at least 100, 150, 175, 200, 210, 220, 250, or even 500. In one embodiment, the filaments have a denier of at most 1200, 900, 800, 700, 600, 500, 400, 350, 300, 250, or even 225 denier.

[0058] An “effective fiber diameter” for a population of fibers is determined by producing one or more magnified images of the fiber population, such as by using a scanning electron microscope; measuring the fiber diameter of clearly visible fibers in the one or more magnified images resulting in a total number of fiber diameters, x; and calculating the average fiber diameter of the x fiber diameters. Typically, x is greater than about 50, and desirably ranges from about 50 to about 2. However, in some cases, x may be selected to be as low as 30 or even 20. These lower values of x may be particularly useful for highly entangled fibers.Non-Woven Porous Fibrous Web for use in Wrinkled Media

[0059] The plurality of elastic filaments is positioned between two non-woven porous fibrous webs, herein referred to as a non-woven web. The nonwoven webs of the present disclosure can be made by wet laid, carded, air laid, spunlaced, spunbonding or melt-blowing techniques or combinations thereof. The nonwoven webs herein may also be formed of split fibers. The nonwoven webs herein may also be formed of fibrillated film (for example that described in US Patent RE32171, published on June 3, 1986).

[0060] In some embodiments, a nonwoven web may undergo a relofting step after formation to increase loftiness. The nonwoven webs may also include or be composed of a scrim or netting. The nonwoven webs may comprise nanofibers produced by electrospinning processes and the like. Spunbonded fibers are formed by extruding molten thermoplastic polymer as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded fibers being rapidly reduced. Meltblown fibers are typically formed by extruding the molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into a high velocity, usually heated gas (e.g., air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Any of the non-woven webs may be made from a single type of fiber or two or more fibers that differ in the type of thermoplastic polymer and / or thickness.

[0061] Suitable thermoplastic polymeric materials include, but are not limited to, polyolefins (such as polypropylene, or polyethylene), poly(isoprenes), poly(butadienes), fluorinated polymers, chlorinated polymers, polyamides, polyimides, polyethers, poly(ether sulfones), poly(sulfones), poly(vinyl acetates), polyesters such as poly(lactic acid), copolymers of vinyl acetate, such as poly(ethylene) -co-poly(vinyl alcohol), poly(phosphazenes), poly(vinyl esters), poly(vinyl ethers), poly(vinyl alcohols), and poly(carbonates).

[0062] Suitable polyolefins include, but are not limited to, poly (ethylene), poly(propylene), poly(l-butene), poly-4-methyl- 1 -butene, copolymers of ethylene and propylene, alpha olefin copolymers (such as copolymers of ethylene or propylene with 1 -butene, 1 -hexene, 1 -octene, and 1 -decene), poly(ethylene-co-1 -butene) and poly(ethylene-co-l-butene-co-l -hexene).

[0063] Suitable polyamides include, but are not limited to, typical nylon polymers such as poly(iminoadipoyliminohexamethylene), poly(iminoadipoyliminodecamethylene), and polycaprolactam. Suitable polyimides include, but are not limited to, poly(pyromellitimide).

[0064] Suitable poly(ether sulfones) include, but are not limited to, poly(diphenylether sulfone) and poly(diphenylsulfone-co-diphenylene oxide sulfone).

[0065] Suitable copolymers of vinyl acetate include, but are not limited to, poly(ethylene-co-vinyl acetate) and such copolymers in which at least some of the acetate groups have been hydrolyzed to afford various poly( vinyl alcohols).

[0066] The fibers selected for the non-woven web depend upon the kind of particulate to be filtered. Particularly useful fibers include webs of melt-blown fibers, such as those disclosed in Wente, Van A., "Superfine Thermoplastic Fibers", 48 Industrial Engineering Chemistry, 1342 et seq (1956). Webs of meltblown fibers provide especially good filtration layers when used in a persistent electrically charged form (see U.S. Pat. No. 4,215,682 to Kubik et al). Preferably, these melt-blown fibers are microfibers having an effective diameter of at least 4, 6, 8 or even 10 micrometers and at most 12, 14, 16 or even 20 micrometers. Other particularly useful filtration fibers are electrically-charged-fibrillated-film -fibers as disclosed in U.S. Pat. No. RE 31,285 to Van Turnhout. Rosin wool fibrous webs and webs of glass fibers are also useful, as are solution blown, or electrostatically sprayed fibers, especially in microfiber form.

[0067] The non-woven webs are porous, meaning that the outside surface of one side of the non-woven web is in fluid communication with the outside surface on the opposing side of the same non-woven web. This ensures flow of vaporous fluids, air, or liquids through the non-woven web. The non-woven webs are coextensive meaning that the web is a complete, continuous layer of non-woven material with no rips or tears.

[0068] In one embodiment, at least one of the non-woven webs of the present disclosure comprises electret fibers. Electrets are a dielectric material that possess a quasi-permanent electric charge or dipole polarization. Electrets typically are improved by incorporating a charging additive into a polymeric material and then inducing a charge onto the polymeric materials using a corona treatment, a tribocharging treatment, a hydrocharging treatment, or combinations thereof. In one embodiment, the electret fibers are monocomponent fibers. In another embodiment, the electret fibers are bicomponent fibers, such as sheathcore, side-by-side, etc. In one embodiment, the electret fibers are sheath-core fibers comprising a core having a coextensive sheath layer disposed thereon. In one embodiment, the core comprises an electrostatic charge enhancing additive. In one embodiment, the sheath comprises an electrostatic charge enhancing additive. In one embodiment, the electret fibers are side-by-side, wherein the fiber comprises two components lying next to each other along the length of the fiber. In one embodiment, the electret fibers are so called “islands-in-the-sea” extrudates, wherein multiple fiber cores (i.e., more than 1, 2, 4, or even 6 cores) are distributed within a polymer matrix, which also forms the sheath.

[0069] Many charge enhancing additives for making electret-containing fiber webs are known in the art. Exemplary electrostatic charge enhancing additives may include pigments, light stabilizers, primary and secondary antioxidants, metal deactivators, hindered amines, hindered phenols, metal salts, phosphitetriesters, phosphoric acid salts, fluorine-containing compounds, and combinations thereof. Preferably, the charge enhancing additive is a solid at ambient conditions to prevent migration within the resin and does not decompose at moderate temperatures. In one embodiment, the charge enhancing additive is a solid at temperatures of at least 25, 30, 40, 50, 60, 80 or even 100°C. In one embodiment, the charge enhancing additive does not decompose, for example, there is no significant weight loss (i.e., less than 5, 1, or even 0.1 wt %) when measured under nitrogen by thermogravometric analysis using a ramp rate of 10 °C / min to heat up to 235 °C.

[0070] Particularly preferred change enhancing additives include hindered amine-based additives, triazinebased additives, and hindered phenol-based additives.

[0071] Specific examples of the hindered amine-based or triazine-based additives include (poly[[6-(1,1, 3, 3, -tetramethylbutyl) amino]-s-triazine-2,4-diyl][[(2,2,6,6-tetramethyl-4- piperidyl) imino] hexamethylene [(2,2,6, 6-tetramethyl-4-piperidyl) imino]]), available under the trade designation “CHIMASSORB 944” from BASF, Ludwigshafen, Germany; dimethyl succinate- l-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethylpiperidine polycondensate, available under the trade designation “TINUVIN 622” from BASF; di-tert-butyl-4-hydroxybenzyl)-2-n-butyl malonate bis(l,2,2,6,6-pentamethyl-4-piperidyl available under the trade designation “TINUVIN 144” from BASF; a poly condensate of dibutylamine- 1 ,3,5-triazine-N,N'-bis(2,2,6,6-tetramethyl-4-piperidyl- 1 ,6-hexamethylenediamine-N-(2,2,6,6-tetramethyl-4-piperidyl)butylamine, available under the trade designation “CHIMASSORB 2020” from BASF; 2-(4,6-diphenyl-l,3,5-triazin-2-yl)-5-((hexyl)oxy)-phenol, available under the trade designation “TINUVIN 1577” from BASF; N-substituted amino aromatic compounds, particularly triamino substituted compounds, such as 2,4,6-trianilino-p-(carbo-2'-ethylhexyl-r-oxy)-l,3,5-triazine, available under the trade designation “UVINUL T-150” from BASF; and 2,4,6-tris-(octadecylamino)triazine, also known as tristearyl melamine ("TSM").

[0072] Hindered phenol-based additives having a hydroxyl group as the terminal functional group, he hindered phenol-based additives are not particularly limited, and specific examples include pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (Irganox 1010, manufactured by BASF), octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate (Irganox 1076, manufactured by BASF), tris-(3,5-di-tert-butyl-4-hydroxybenzyl)-isocyanurate (Irganox 3114, manufactured by BASF), 3,9-bis-{2-[3-(3 -tert-butyl-4-hydroxy-5 -methylphenyl) -propionyloxy] -1,1 -dimethylethyl } -2,4,8, 10-tetraoxaspiro-[5,5]undecane (Sumilizer-GA-80, manufactured by Sumitomo Chemical Co., Ltd.), and the like.

[0073] Additional thermally stable organic triazine compounds or oligomers, which compounds or oligomers contain at least one nitrogen atom in addition to those in the triazine ring, are disclosed in U.S. Patent Nos 6,268,495, 5,976,208, 5,968,635, 5,919,847, and 5,908,598 to Rousseau et al.

[0074] Further examples of charge -enhancing additives are provided in U. S. Publ. No. 2011 / 0137082 (Li et al.). U. S. Pat. Nos. 8613795 (Li etal.), 7,390,351 (Leir et al.), U. S. Pat. No. 5,057,710 (Nishiuraet al.), and U. S. Pat. Nos. 4,652,282 and 4,789,504, both to Susumu et al., and U. S. Pat. No. 8,790,449 B2 (Li et al.).

[0075] The charge-enhancing additive(s) can be added in any suitable amount. The charge-enhancingadditives of this disclosure may be effective even in relatively small quantities. Typically, the chargeenhancing additive is present in a thermoplastic resin and charge -enhancing additive blend in amounts of up to about 10 % by weight, more typically in the range of 0.02 to 5 % by weight based upon the total weight of the blend. In some embodiments, the charge -enhancing additive is present in an amount ranging from 0.1 to 3 % by weight, 0.1 to 2 % by weight, 0.2 to 1.0 % by weight, or 0.25 to 0.5 % by weight.Membrane and Non-woven Porous Web with Sorbent for use in Wrinkled Media

[0076] Alternatively or additionally, a porous membrane may be used in place of, and / or combined with the non-woven fibrous web. The membrane may be a polyolefin porous membrane, a polyacrylonitrile porous membrane, a polycarbonate porous membrane, a polyester porous membrane, a cellulose ester porous membrane, a polyamide porous membrane, a polyethersulfone porous membrane, a polysulfone porous membrane, a polyacrylonitrile nanofiber membrane, a PVDF nanofiber membrane, a cellulose ester nanofiber membrane, a polyvinyl acetate or alcohol nanofiber membrane, a nylon membrane, or a polyvinyl butyral nanofiber membrane.

[0077] The membrane can be made by, for example, TIPS (thermally induced phase separation) process, SIPS (solvent induced phase separation) process, VIPS (vapor induced phase separation) process, stretching process, track-etching, or electrospinning (e.g., PAN fiber membranes).

[0078] A wrinkled membrane may be wrinkled, for example, using the techniques described herein above with respect to FIGS. 2A-2B. The plurality of elastic filaments is positioned between a membrane layer and one or more non-woven porous webs. The membrane layer may include membrane and one or more nonwoven webs stacked or laminated or bonded.

[0079] Alternatively, or additionally, the non-woven porous web may include a sorbent material. The sorbent particles may be disposed on the surface of non-woven web or throughout the depth of non-woven web. One example of the sorbent material is activated carbon either untreated or chemically treated. Other sorbent materials such as polymeric sorbent may be used as well.Method of Making Wrinkled Media

[0080] In one embodiment, the wrinkled filter media of the present application can be made by stretching a first series comprising a plurality of elastic filaments. The filaments are not generally bonded to one another (for example, the filaments of the present disclosure are not a scrim). The plurality of elastic filaments in the first series are held (for example using a spacer) such that each of the filaments is substantially parallel to one another and are spaced a given distance apart. Generally, the substantially parallel filaments should not touch the nearest neighbor filament in the working portion of the finished good. In one embodiment, the elastic filaments are held with a spacing of at least 2, 4, 5, or even 6 filaments per inch. In one embodiment, the elastic filaments are held with a spacing of at most 8, 10, 12, 15, 20, or even 25 filaments per inch. Generally, the spacing of the filaments is selected to achieve the desired shirring of the non-woven web without causing a large change in pressure.

[0081] Shown in FIG. 2C is exemplary configuration of a first series of filaments 232, wherein the filaments are tied at either end and combs 235 and 237 are used at both ends to hold the filamentssubstantially parallel. The first series of filaments are placed between first non-woven porous fibrous web 234 and second non-woven porous fibrous web 236. Nonwoven web 236 is placed below the stretched plurality of parallel filaments with the adhesive side contacting the filaments. The second adhesive-sprayed web 234 is placed above the stretched plurality of parallel filaments with the adhesive side contacting the filaments. Then, a cardboard roller compresses the laminate gently to remove any air pockets so that the two nonwoven webs are adhered together with the filaments positioned in between the two webs.

[0082] The manual hold of the stretched plurality of parallel filaments is then released, and the filaments are allowed to relax causing the laminated media (web-adhesive-filament-adhesive-web) to pucker. Additional details of how wrinkled media can be made can be found in PCT Publication 2024 / 137158, published June 27, specifically in paragraphs [0027-0037], which are incorporated herein by reference.

[0083] The filaments can be stretched to any desired length. The % stretch as used herein is defined as the difference between the length of the stretched filament and the length of the initial relaxed filament divided by the length of the initial relaxed filament converted to a percent. In one embodiment, the elastic filaments are stretched to greater than 50, 75, 100, 150, 200, or even 250%. The filaments can be stretched more than 250% so long as the filaments do not go beyond the elastic limit to deformation or break during the manufacturing of the wrinkled media disclosed herein.

[0084] The first and second non-woven webs are positioned on either side of the stretched filaments. The first and second non-woven webs may be the same or different. The non-woven webs are selected based on the desired performance properties. The non-woven webs selected may be different in terms of composition, basis weight, thickness, porosity, etc.

[0085] The first and second non-woven webs are bonded directly together such that the first non-woven web contacts the second non-woven web, optionally with the use of an adhesive as exemplified below. In one embodiment, an adhesive is used to directly bond (or adhere) the first and second non-woven webs together. Such adhesives can include a pressure sensitive adhesive or a hot melt adhesive. Pressure sensitive adhesives are known in the art and are generally adhesives that can adhere based on room temperature conditions when pressure (e.g., finger pressure) is applied. Exemplary pressure sensitive adhesives include: a natural latex or synthetic polymer such as a (meth)acrylate. A commercially available pressure sensitive adhesive includes a spray adhesive available under the trade designation “3M Super 77 Multipurpose Adhesive” by 3M Co., Maplewood, MN, USA. Hot melt adhesives are those adhesives that are thermoplastic polymers which are heated above their softening point and when applied in their softened state to a surface, penetrate the surface and solidify ensuring cohesion. Exemplary hot melt adhesives include: Bostik HM-9041 available from Bostik inc., Wauwatosa, WI, and Tailored HM011BA available from Tailored Chemical Products Inc., Hickory, NC. In the embodiments of the present application when an adhesive is applied, the weight of adhesive used per unit area is less than the weight per unit area of the non-woven web. In one embodiment, the weight per unit area of the adhesive is less than 0.5, 0.4, 0.3, 0.2, or even 0.1 % of the weight per unit area of the non-woven porous fibrous webs in the article. Ideally, the adhesive should not interfere with the performance of the article and should be collapsible, meaning that the adhesive can maintain cohesiveness (or keep the two layers of non-woven webs bonded) upon therelaxing of the stretched filaments during manufacture. In one embodiment, the adhesive is at least 1, 2, 4, 5, or even 6 gsm (grams per square meter) in the wrinkled article. In one embodiment, the adhesive is at most 8, 10, 15, 20, 40, 60, 80 or even 100 gsm in the wrinkled article. In another embodiment, the first and second non-woven webs are welded directly together such that the first non-woven porous fibrous web is in intimate contact with the second non-woven porous fibrous web. Such welding techniques are known in the art and include thermal bonding or ultrasonic welding.

[0086] After bonding (or adhering) the first and second non-woven porous fibrous webs together, the tension is released on the stretched elastic filaments and the resulting article puckers or becomes shirred as represented schematically in FIG. 2A. Typically, after the tension is released on the stretched elastic filaments, it could take upwards of hours or days for the shirred article to achieve its final puckered state as an equilibrium in the construction is reached. In one embodiment, the heat can be used to more quickly achieve this stable state.

[0087] In addition to the first and second non-woven webs, additional layers (e.g., a third layer) may be added to the shirred article to provide additional functionality. The third layer may be added before release of the tension on the filaments, such that the third layer is also puckered or shirred. In another embodiment, the third layer is added after release of the tension on the filaments, such that the third layer is a flat layer bonded to the puckered or shirred article. Exemplary third layers include cover webs, which is a layer used to protect the underlying article from abrasion, soiling, etc. The third layer may also provide cosmetic and visual function.

[0088] In another embodiment, in addition to the first series of elastic filaments, a second series of filaments can also be used, wherein the first and second series of elastic filaments are positioned nonparallel to each other (for example at least 45 degrees or at least 90 degrees apart). The shirred article is made as described above, except that both series of elastic filaments are placed between the two non-woven webs. When tension is released on both series of filaments, the resulting article has a more complex puckered pattern as shown in the Example Section.

[0089] In yet another embodiment, the series of elastic filaments may be stretch to different percentages, such that when the tension is released the resulting puckered material comprises areas with more puckering and areas with less puckering.

[0090] The articles of the present disclosure are resiliently extensible under tension, meaning that when the puckered article is pulled in the same direction as the length of the elastic filaments, the puckered article can elongate (or flatten out) and when the tension is released, the elongated article returns to its puckered form. In one embodiment, the puckered article is elastically extensible to at least 2 or even 3 times of its relaxed length. In some embodiments, the puckered article comprises at least one portion which is resiliently extensible under a first tension, wherein a second portion of the shirred filter media is under a second tension.

[0091] Because the articles of the present disclosure have a puckered (or shirred) appearance, the basis weight of the resulting article has a higher basis weight than the original flat or unwrinkled non-woven porous fibrous webs. In one embodiment, the shirred articles of the present disclosure have a basis weightof at least 10, 15, 20, 30, 40, 50, 75, or even 100 grams per square meter (gsm). In one embodiment, the shirred articles of the present disclosure have a basis weight of at most 100, 125, 150, 175, 180, 200, 225, 250, or even 300 gsm.

[0092] The resulting shirred media is self-supporting meaning that an addition layer is not needed to provide support to the non-woven web / fdament / non-woven web construction, optionally comprising an adhesive. Such articles can be used to fdter out undesirable particles from the fluids, such as dust, molds, oily mist aerosol, cigarette smoke, pet dander, viruses, bacteria, etc.

[0093] The fdter media of the present disclosure described herein may have a variety of suitable air permeabilities. In one embodiment, the fdter media has an air permeability of greater than or equal to 2, 5, 10, 15, 20, 25, 30, 40, 50, 75, 100, 120, 150, 170, 200, 275, 300, 350, 400 or even 450 CFM / sqft. In some embodiments, the fdter media has an air permeability of less than or equal to 450, 400, 350, 325, 300, 275, 250, 225, 200, 170, 150, 120, 100, 75, 60, 50, 40, 35, 30, or even 25 CFM / sqft. Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to 20 CFM / sqft and less than or equal to 350 CFM / sqft, greater than or equal to 35 CFM / sqft and less than or equal to 170 CFM / sqft, or greater than or equal to 20 CFM / sqft and less than or equal to 350 CFM / sqft). Other ranges are also possible. The air permeability of a fdter media may be determined in accordance with ASTM Test Standard D737 (1996).

[0094] Filtration performance test results of shirred media articles are discussed in greater detail in PCT Publication 2024 / 137158, published June 27, 2024, specifically in the Examples, which are incorporated herein by reference.

[0095] FIGS. 2A-2C illustrate wrinkled media that has a stretch along an axis defined by the elastic filaments. Wrinkled media may be incorporated into a respirator body - e.g. body 11 of FIG. 1A. The wrinkled media may be incorporated such that the respirator body stretches along a length of the respirator - e.g. the distance between earloops 13, along a height - e.g. perpendicular to the length, or the wrinkled media may be aligned such that the stretch is angled with respect to the length - for example at a 30°, a 45°, a 60°, a 75°, a 110°, a 120°, 130°, 140°, 150°, 160° or 170° to either the length or the height of the respirator. A respirator body having stretch along an angle may help a respirator provide a better fit for a smaller face.

[0096] FIGS. 3A-3C illustrate RPDs with customizable face seals in accordance with embodiments herein. FIGS. 3A-3C illustrate embodiments where a face seal is formed from wrinkled media, which may increase an ability for the face seal to stretch and conform to the face of a user. However, it is expressly contemplated that some embodiments herein include face seals formed from flat media. Additionally, while FIGS. 3A-3C illustrate wrinkled media face seals in a configuration where the material stretches primarily in a horizontal direction, it is expressly contemplated that the wrinkled media face seal may be coupled to an RPD body such that the stretch is primarily in the vertical direction, primarily in a direction angled with respect to the horizontal direction.

[0097] FIGS. 3A and 3B may be representative of an RPD as a customer may receive it. FIG. 3A illustrates an RPD 300 with a face seal 310 sealed to the perimeter 302 of the body. Face seal 310 may be sealed to RPD using any suitable sealing mechanism including, but not limited to, welding, ultrasonic welding, stitching, adhesive, or a combination thereof. In some embodiments, a user may receive or purchase anRPD that has an intact face seal 310, e.g. with an uninterrupted surface. In some embodiments, an aperture (e.g. an aperture like aperture 370 of FIG. 3C or smaller) may be present.

[0098] Face seal 310 may be configured with one or more face size indications 312, 314, which may allow for a user to customize the RPD to provide a better fit to their face. As illustrated in FIG. 3 A, a user may select to remove material along either the “small” size indication line 312 or the “large” face size indication line 314. Indication lines 312, 314 may include a visual indicator - e.g. a perimeter to remove printed on face seal 310, in some embodiments. In some embodiments, indication 312, 314 may include a removal feature - e.g. at least some perforations, bum or melt lines, point-bonding, weld lines, or apertures that allow a user to more easily tear along indication lines 312, 314. In some embodiments, indication lines 312, 314 include both a visual indicator and a removal feature.

[0099] FIG. 3B illustrates an RPD 330 with a face seal 340 adhered to the perimeter. In addition to a face size indication line 342, FIG. 3B illustrates an embodiment where a nose portion of a face seal may be configured - for example by removing either area 352 or area 354. Depending on the size and shape of a user’s nose, a larger or smaller cutout may provide a better fit. While both nose areas defined by indicator lines 352, 354 are illustrated as triangular in shape, with a pointed tip, it is expressly contemplated that other shapes may be possible. For example, a user may not remove any area, but only slit the face seal in the nose area to improve fit. A half-circle or half-oval shape may provide a better fit for some users. Other shapes, such as a rounded triangle, rectangular, higher-level polygonal or even a non-polygonal shape may also be useful, depending on a user’s face shape. While FIG. 3B illustrates only two custom nose area indications 352, 354, it is expressly contemplated that more, or fewer, may be shown in some embodiments.

[0100] FIGS. 3A-3B illustrate dashed-line based indicators for forming apertures. However, it is expressly contemplated that indications for where a user should remove material may be presented in any suitable way. For example, a solid or dotted outline may be printed on the material, and / or a tactile indication such as point bonds, welds, or perforations may be present.

[0101] FIG. 3C illustrates an RPD 360 with a face seal configured for a user. For the illustrated RPD 360, an aperture 370 has been made in face seal 340, for example based on a face seal size indication and a nose area indication for a particular user, producing customized face seal 380. The customized face seal 380 may, for example, represent a removal of over about 30% of an area of face seal 340, or of over about 40% of face seal 340, or of over about 50% of face seal 340, or of over about 60% of face seal 340, or more.

[0102] FIG. 3D illustrates an RPD with an irregular polygon-shaped face seal indicator 390. It is expressly contemplated that a face seal shape may be customized in a number of ways to fit any number of facial configurations. For example, a modified face seal may help extend a range of fit of some respirators such that they may provide respiratory protection to some children. Additionally, individuals having longer and narrower faces may be better fit by a face seal with a reduced roundness to the face seal perimeter. Face seal indication 390 illustrates a five-sided shape aperture, however it is expressly contemplated that a polygon having any number of sides may be suitable. For example, a triangle, a quadrilateral, a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, etc. As illustrated in FIG. 3D, in someembodiments the polygonal face seal indication 390 is an irregular polygon. However, it is expressly contemplated that regular polygon-shaped apertures may be useful for some facial geometries.

[0103] FIG. 3E-1 to 3E-3 illustrate how a user may interact with a face seal marked by a coordinate grid system. FIG. 3E-1 and 3E-2 illustrate how a grid system may be printed, or stitched or otherwise marked onto a face seal. The grid may include alphanumerical indications, in some embodiments, or other suitable markings. A user may be able to follow instructions (e.g. tear along vertical line three from horizontal line 1-9, etc.) to form an aperture that is appropriately sized for their face. FIG. 3E-3 illustrates an example aperture that may be formed.

[0104] It is expressly contemplated that, in accordance with embodiments herein, a face seal is coupled to a respirator body prior to any modifications. Respirators in embodiments herein are intended to be purchased, or obtained, by a user prior to individual customization. It is expressly contemplated that a manufacturer sealing a face seal to a respirator body is preferred in order to reduce the chance of leaks along the exterior of the face seal where it is coupled to the respirator body. The face seal may be coupled to the respirator body using any suitable mechanism that results in a suitable seal - stitching, adhesive, bonding, point-bonding, welding, ultrasonic welding, etc.

[0105] FIG. 4 illustrates a method of fit testing in accordance with embodiments herein. While it is expressly contemplated that RPDs described herein are useful on their own, RPDs having one or more customizable fit options may be particularly useful when used as part of a digital fit testing experience.

[0106] Fit testing can be done, as described in U.S. Provisional Patent Application with Ser. No.63 / 584916, filed September 25, 2023, for example, using an image capturing device, or equivalent technology, to capture an image of a user’s face. No additional physical sensors are required. Additionally, no predetermined size reference (e.g., a coin, iris size, etc.) is required for embodiments herein. Systems and methods herein utilize machine learning algorithms, stored in a memory and executed using suitable processing circuitry, to analyze the face of a user with and without PPE and, based on said analysis, determine a likelihood of fit. For respirators, a likelihood of fit may be calculated based on determining facial dimensions, facial landmarks and distances / angles therebetween, or otherwise comparing the captured image to a set of training images to determine a fit likelihood, described herein as a “fit factor.”

[0107] Method 400 may be implemented using a device with an image capturing device or other suitable sensor (e.g., laser scanning, etc.), a memory and suitable processing circuitry. Calculations and analysis may be completed locally or remotely.

[0108] In block 410, a user is scanned. Scanning a user may include capturing an image of a user relevant to a PPE article - e.g., a user’s face for a respiratory device, safety glasses, or helmet, or a user’s ear for a hearing protection article, a user’s body for fall protection or coveralls, etc. Scanning may be done using an image capturing device in some embodiments, such as a camera, video camera or other suitable device. However, scanning may be done using other suitable systems, such as a laser-based scanning system or another suitable scanning system. Any suitable system that obtains sufficient topographical information about a user may be utilized as a scanning system herein.

[0109] In block 420, landmarks are identified based on the scan. Landmarks may include, in the exampleof respirator fit testing, cheek bones, nose tip, chin, etc. The listed landmarks are provided for example only - it is expressly contemplated that many more suitable landmarks are possible. In some embodiments, the landmarks are identified using a machine learning algorithm trained on a set of images of users with known landmarks. It is noted that previous respirator recommendation systems based a recommendation on only a few measurements - such as a facial length, facial width, interpupillary distance, etc. Systems and methods herein may identify as many as 5-10 landmarks on a user’s face during a respirator fit test, in some embodiments. Systems and methods may even identify as many as 20 landmarks on a user’s face during a respirator fit test, or even as many as 25, or even more. Systems and methods may even identify as many as 50 landmarks on a user’s face during a respirator fit test, or even as many as 100, or even more.

[0110] In block 430, the identified landmarks are analyzed. Analyzing landmarks may include comparing landmarks to each other - e.g., determining a distance between landmark 1 and landmark 2, or an angle formed by landmarks 1, 2, and 3, etc. In some embodiments, over 50 datapoints are calculated based on the landmark analysis. In some embodiments over 100 datapoints are calculated based on the landmark analysis. In some embodiments, over 200 datapoints, or even over 300 datapoints, or even over 500 datapoints are calculated based on the landmark analysis. In some embodiments, some datapoints are weighted differently than others for analysis purposes.[oni] In block 440, a PPE model selection is received. In some embodiments, systems and methods herein may provide one or more suggested PPE models for a user, based on the landmark analysis. A PPE model selection may be received by an I / O device, e.g., a touchscreen, a mouse, a keyboard, etc. based on a user’s input. A PPE model selection may also be made by scanning a barcode, recognizing the PPE model selection in a scan or image, etc.

[0112] In block 450, a face seal size is suggested for the user based on the facial scans and the detected PPE. For example, an individual with a smaller face may select a disposable respirator with two different size options for a face seal. The face seal more suitable for the individual may be recommended.

[0113] In block 460, a nose portion area may be suggested based on the facial scans and the detected PPE.For example, a user may receive a recommendation that no additional modifications are needed, beyond making the appropriate face seal adjustment. Alternatively, a user may be given a recommendation to make a slit or to remove an area of the face seal to better accommodate the geometry of their nose. The removal instructions may take any suitable form. For example, in some embodiments a pattern is printed on the face seal that makes removal easier. A coordinate grid, for example, may provide a basis for custom material removal, which may be particularly useful for accommodating asymmetry in some users’ faces. However, other patterns are possible - including lines or curves indicative of different size or shape options. The different potential options may be indicated using solid lines, dashed lines, dotted lines, in different colors, or in any other suitable manner that allows a user to visually distinguish and follow.

[0114] In some embodiments, the face seal may be prepared for removal - e.g. with perforations along at least one potential face seal size, or with welds, point-bonding, or another suitable mechanism for guiding material removal.

[0115] In some embodiments, a removal aid is built into the face mask. For example, a tab may be availablethat a user can pull. When pulled, the tab may cause material to be removed along a predetermined line. The tab may, in some embodiments, be attached to a guide (e.g. a plastic strip embedded, adhered, bonded or otherwise coupled to the face seal) that, when removed, also removes a portion of the face seal.

[0116] In block 470, in some embodiments, a scan is taken of a user wearing the modified article of PPE.The scan may be taken with any suitable scanning system. In some embodiments, the same system used in block 410 is used for the scan in block 470. In some embodiments, a different system may be used. For example, instead of actively scanning a user in block 410, a previous scan of a user could be retrieved.

[0117] In block 480, the scans of the user before and after donning the article of PPE are compared to determine potential fit inconsistencies. The comparison may be done using a machine learning algorithm. For respirator fit testing, fit inconsistencies may be gaps where environmental air may leak into the breathing zone within the respirator cavity. In some embodiments, a comparison includes comparing the way a PPE lays on the body part in a current scan with the way the PPE laid on the same body part in a scan captured after a successful fit test and determining a difference. In some embodiments, comparing includes mapping landmarks and determining which landmarks should be obscured by the PPE, and by how much.

[0118] Identified inconsistencies may be evaluated. The evaluation may be done, for example, by a machine learning algorithm, look-up tables, or another suitable method to determine if the identified gaps are significant enough to cause failure of a fit test.

[0119] In some embodiments, a fit test result is generated. For example, if identified inconsistencies are insignificant, a “fit test pass” indication may be provided. If the identified inconsistencies are significant enough to cause failure of a fit test, a “fit test failed” may be provided. In some embodiments, generating a fit test result includes generating a fit factor. The fit factor may be provided in addition to, or instead of, a fit test pass or fail indication.

[0120] It is noted that, in some embodiments, a number of landmarks to be detected and / or datapoints to calculate may be specified for a landmark detector and / or analyzer. However, it is expressly contemplated that a machine learning algorithm may find correlations based on training data without correlation.

[0121] Systems and methods herein generate a fit test result automatically based on a comparison between a pre and post scan of a user donning a PPE article. The fit test result may be physically generated, for example sent to a printer for printing on paper, or another suitable medium. Generating a fit test result may also include generating the result in a manner that makes regulatory compliance, or audit compliance, more convenient. Generating the result may also include generating a physical or digital copy that is provided to an employer, for employer records. Generating the result may also include generating a digital or physical copy for the worker. For example, the worker may have an account, or otherwise have access to at least some of information accessible using systems herein.

[0122] Systems and methods herein also automatically generate a digital fit test record for a fit test. This contrasts with traditional fit testing which requires recording all test results, for example in a spreadsheet, capturing the test result record, and then compiling and emailing the records to a site safety manager.

[0123] Instructions for properly customizing an RPD face seal may be provided in any suitable matter. Forexample, if a user is completing method 400 using an application for a mobile computing device, instructions may be provided using the user interface of the mobile computing device. Instructions for forming the custom face seal may be provided, for example as an overlay over an image of the RPD, a diagram, or in any suitable manner. In some embodiments, the user may be prompted to scan or image the RPD after the modifications have been made to the face seal so that the accuracy of the user’s actions can be evaluated.

[0124] Fit modifications described with respect to FIGS. 3-4 include selecting a face seal size and a nose area shape. However, it is expressly contemplated that additional modifications may be possible. For example, a chin portion of the face seal may also be modifiable. Additionally, the face seal may be further modifiable in other ways for users with bums, scars and / or facial hair to improve fit.

[0125] FIGS. 5A-5C illustrate an RPD with adjustable straps in accordance with embodiments herein.

[0126] Respiratory devices come in a number of models, some of which are disposable while others are reusable. One important aspect of respirator comfort is how tightly a respirator is forced against a user’s face. Often, in an attempt to obtain a better seal, users will over-tighten respirator straps, which can decrease comfort with negligible improvements in fit. Similarly, a user may opt for a disposable respirator with shorter straps in an attempt to improve fit, while a similar respirator with longer straps may provide more comfort without significant reduction in fit. Comfort of PPE for users, and methods of calculating deformation of a user’s face is also discussed in US. Patent Application Publication 2023 / 0290091, published September 14, 2023.

[0127] FIG. 5A illustrates a side view of a user wearing a reusable respirator 500, which has two straps -strap 510, configured to be worn over-the-ears, and strap 520, configured to be worn under-the-ears. Illustrated in FIG. 5A, each of straps 510, 520 includes a geometric pattern 530. Geometric pattern 530 can be used by a computer vision system to determine whether a wearer’s straps are tight enough, or at what tightness they can be set to increase comfort while maintaining a satisfactory fit. A computer vision system may also be able to calculate forces exerted on the wearer’s face. Systems and methods herein may also provide instructions for a user to put on, and tighten, a respirator. A user may be recommended, for example, to change a position of a strap - e.g. if a user has placed both straps below their ears, systems and methods herein may provide instructions on correct placement.

[0128] FIGS. 5B-5C illustrate how a geometric pattern may change as an associated strap is stretched.

[0129] While FIG. 5B illustrates one example of a strap tightness indicator pattern, it is expressly contemplated that other patterns are possible, for example colored markings may be used, or another different geometric pattern. The pattern may be printed onto a strap, sewn into the strap, or otherwise suitably coupled such that it is not easily removed during use. In some embodiments, the pattern is built into the stitching pattern such that a separate printing / stitching step is not needed. Additionally, ultrasonic welding is often used to secure the end of a strap such that it is stopped from completely passing through the buckle for the strap. In some embodiments, ultrasonic welding is also used to create the geometric pattern.

[0130] As illustrated in the transition between FIGS. 5B-5C, the geometric pattern changes as the strap isstretched. A geometric pattern 550 may include multiple units - e.g. x, 2x, 3x, which, when stretched, transform into geometric pattern 560 having y, 2y, 3y (shown in part). Additionally, a width 554 of the strap may also narrow to width 564 when stretched.

[0131] Geometric pattern 550 is formed of two vertical lines, with increasing distance between them. In some embodiments this repeats after two pattern units (e.g. x, 2x, x, 2x, etc.). The strap is stretched around a 3D surface (a user’s head), however the portion of the strap from the respirator to the buckle is relatively flat, providing a surface from which tension can be estimated.

[0132] A computer vision system, knowing the model of respirator, can access a database with information about unstretched pattern 550, as well as information about how pattern 560 stretches. When a user wearing a respirator with pattern 560 is captured, it is possible to measure the change from angle 552 to angle 562, the change in distances x vs. y, 2x vs. 2y, 3x vs. 3y and / or the change in width 554 to width 564. A percent extension can then be calculated using trigonometry, which can then be used against a force-extension curve database to obtain a headband force. However, it is expressly contemplated that other mathematical model bases may be used to calculate force or determine whether a strap is over or under-stretched for a user.

[0133] For example, other shapes such as circles or ovals may be used, in some embodiments. Additionally, instead of lines, patterns of dots may be used.

[0134] In some embodiments, instead of a geometric pattern, two colors of material are used such that, when the material is stretched, more of the second color is visible - e.g. a weave of artificial rubber and polyester may include two different color materials - as the rubber stretches, the relative amount of that corresponding color would increase in a detectable and measurable way.

[0135] While visual indicators are described herein, it is also contemplated that indicators in the IR spectrum may also be used and be detected by a PPE fit testing or monitoring system having an IR-enabled camera.

[0136] FIG. 5D illustrates an example force curve for a respirator that can be used to determine an amount of force that is applied to a user’s head. As different respirator straps stretch at different rates, systems and methods herein may rely on a database of force-extension curves, such as that illustrated in FIG. 5D, for different respirators. When a respirator is identified by a vision system, in addition to retrieving pattern information, a force-extension curve may be retrieved so that the detected stretch (e.g. extension) can be related to an applied force. The computer vision system may then be able to provide a recommended extension based on a target amount of force that correlated with a good fit. As illustrated in the Examples below, users often significantly over-extend respirator straps. A computer vision system may, in embodiments herein, identify an indication on a respirator strap, retrieve correlation information for the particular respirator model, and provide an instruction for adjusting a strap tension. In some embodiments, an applied force is calculated, using a force curve such as that illustrated in FIG. 5D.

[0137] FIG. 6 illustrates a method of fitting an RPD in accordance with embodiments herein. In some embodiments, method 600 may be performed in parallel with blocks 450-480 of method 400. For example, a user may select an RPD model based on a PPE recommendation from a fit testing or fit evaluation system, in some embodiments and, after the user dons the PPE, method 600 may proceed to determine whether ornot a headband strap or harness is positioned correctly. In some embodiments, method 600 takes place after a user has selected an RPD model without input from a fit testing or fit evaluation system. For example, method 600 may be incorporated into a computer vision system that captures an image of a user wearing an RPD and proceeds to automatically determine whether or not the RPD is appropriately worn by a user.

[0138] At block 610, a user wearing an RPD with adjustable straps is scanned. The scan may be done by a camera on a mobile device, for example using a fit testing or fit evaluation mobile application. The scan may be done by a camera within a working environment, for example as a user passes through the camera’s field of view. In some embodiments, scanning includes capturing a view of a user’s face and / or capturing a side view of a user.

[0139] At block 620, fit indications are identified. Based on the scan, a computer vision algorithm may identify one or more fit indications for the RPD. Fit indications may include detecting a placement of a strap on a user’s head - e.g. above the ear, below the ear, along the neck, etc. Fit indications may also include indications about a tightness of a strap about a user’s head. For example, a geometric pattern, or other indication of stretch may be detected on a strap of the RPD.

[0140] At block 630, the fit of the RPD is analyzed. Analysis may include retrieving data regarding a detected model of the RPD. Different models of RPDs may have different fit indicia. With respect to the straps of the RPD, analysis may include determining whether one or more straps are placed in a good position. For some two-strap RPD models, for example, it is preferred to have one strap placed above the ears and one strap placed below the ears. Analysis may include comparing the detected strap positions to the preferred positions.

[0141] Analysis may also include determining whether a user has tightened the straps sufficiently, or whether the user has overtightened them, and can loosen them to increase comfort. Tightness may be detected, at least in part, based on an amount of stretch of a strap. A strap may have one or more detectable indications of stretch - such as the geometric pattern illustrated in FIGS. 5B-5C, for example, or another suitable pattern. The stretch indication may also be color based - often straps are formed from multiple materials. Having a particular color for an elastic material will result in that color becoming more prominent as the strap is stretched, and more area of the elastic material is visible. Other fit indications may be present in other embodiments.

[0142] At block 640, instructions are provided to a user on how to improve the fit and / or comfort of their RPD. For example, a user may be instructed to tighten one or more straps, move one or more straps, or may be told to loosen one or more straps to increase comfort. A user may be instructed to repeat method 600, for example, after straps are loosened, tightened, or repositioned to ensure that fit is maintained. Instructions may be provided using a mobile application interface, using a display communicably coupled to the device implementing method 600, audibly, or in any other suitable manner.

[0143] FIG. 7 illustrates an RPD with a wrinkled-media based harness in accordance with embodiments herein. In some embodiments herein, an RPD includes a harness that is formed from wrinkled media. Using wrinkled media may allow for increased comfort as the material has an ability to stretch. Additionally, wrinkled media may allow for the manufacture of a unitary RPD, such as RPD 700, where a body 720 anda harness 710 are both formed from wrinkled media.

[0144] Respiratory protection devices in embodiments herein differ from surgical masks or cloth face coverings in that respiratory protection in compliance with one or more international standards is provided. Respiratory protection devices, or respirators, in accordance with embodiments herein may be in compliance with the NIOSH N95 standard, e.g. such that at least 95% of airborne particles having a diameter of 0.3 pm under standard conditions are captured by the fdter. In some embodiments herein, respiratory protection devices fdter at least 99%, or at least 99.97% of airborne particles having a diameter of 0.3 pm under standard conditions are captured by the fdter. Respiratory protection devices in accordance with embodiments herein may also be somewhat or strongly resistant to oil, for example with any of the R95, P95, P99 or P100 standards.

[0145] FIG. 8 illustrates a PPE evaluation system in accordance with some embodiments herein. Systems and methods herein may provide digital fit testing functionality, but may also provide recommendations of, and information specific to, PPE of interest to a given individual as well as evaluate fit of a given PPE for a given individual.

[0146] FIG. 8 illustrates a block diagram of one embodiment of a PPE evaluation system 400. System 800 includes an image receiver 822 configured to receive an image of a user. For example, a user’s face may be scanned for fitting a respirator, a user’s ear may be scanned for fitting a hearing protection article, a user’s entire body may be scanned for fitting a fall protection harness or coveralls, etc. These scans may be received by image receiver 822 contemporaneously from an image capturing device, in some embodiments. In some embodiments, based on identifying a user, PPE evaluation system 800 retrieves an image, or sufficient image data, from a datastore. For example, a user may log into a mobile application with the functionality of FIG. 8. Based on the user’s login, information about the user may be accessible or retrievable by receiver 824. For example, a previous image of a user may be retrieved and / or previously obtained fit test data for one or more RPD models may be retrieved. A face seal size or nose portion shape may be retrieved, for example. Other relevant information about a user’s RPD selection or customization may be retrieved using retriever 820. For example, retriever 820 may retrieve information about available RPDs for a user - e.g. based on RPDs known to be available at a worksite, based on the user’s RPD use history, or based on other sources. Additionally, an inter-pupillary distance for a user may already be known and retrievable. This may be helpful for testing whether a received image is a suitable representation, or whether a mesh has been correctly applied to a detected face.

[0147] A user of system 800 (e.g., a worker within a site) may be scanned using a scanning device 412, which may be any suitable device that captures PPE fitting data. For example, a laser scanning system such as LIDAR may be used to obtain topographical information about a user. Other suitable scanning technology is expressly contemplated such as 3D time of flight, e.g. scanner-less LIDAR, stereo cameras, ultrasonic sensors, or using structured light. A camera may be used to capture an image of a user. Other suitable scanning technology is expressly contemplated such as 3D time of flight, e.g., scanner-less LIDAR, or using structured light. A scanning module (not shown in FIG. 8) may include a scan actuator configured to trigger scanning device to obtain scanning data. For example, scan actuator may trigger a scan, forexample, based on a user input - e.g., a user providing an indication that they are ready for a scan to take place. A scan actuator may also trigger a scan, in some embodiments, automatically. For example, scan actuator may detect that a relevant part of a user is positioned within a scanning frame (e.g., in front of a laser detector, within a frame of a camera, etc.) and start a scan without receiving a user indication. Scan actuator may also, in some examples, start a scan on a delay - e.g., a warning may be given to a user to “stand still,” and a scan may start within a few seconds of the warning. As used herein, “user indication” means any data item or set of data associated with a particular wearer that is obtained or retrieved by the system for use in selecting, analyzing, or customizing the fit of personal protective equipment. A user indication may be raw sensor or image data, processed or derived features, metadata, or previously stored records, and may be captured contemporaneously or retrieved from a datastore.

[0148] A scanning module may include a light source. For example, if a user is in a dark environment, light may be needed in order to illuminate features important to detecting a fit. For example, fitting a respirator may require an image with facial features (nose, chin, eyes) clearly detectable. Scan actuator may actuate light source based on an indication that ambient light is not sufficient. For example, light source may be turned on if a camera detects ambient light below a light threshold.

[0149] A landmark detector 830 may, based on received scan data, detect one or more landmarks of interest. In some embodiments, landmark detector detects one or more landmarks based on a mesh generated by a mesh applicator 832. Landmarks may include user specifications such as top of head, eyebrow ridge, a position of a cheek bone, a chin location, etc. Other landmark options are expressly contemplated. Landmark detector 830 may detect landmarks only for evaluating fit of a particular RPD, or it may be configured to detect landmarks for multiple PPE simultaneously - e.g. a first set of landmarks for fit testing multiple types of PPE - for example a first type of PPE (e.g., facial landmarks for a respirator) and a second set of landmarks for fit testing a second type of PPE (e.g. body landmarks for a fall protection harness). Landmark detector 830 may detect landmarks based on a known PPE being fit tested - for example a user may designate that a fit test for a respirator is needed.

[0150] Landmark data may, based on the detected landmarks, be generated for the user. A landmark analyzer 830 may quantify a user’s relevant dimensions so that a fit can be estimated by fit estimator 814 and / or so that a comfort estimate can be generated by comfort estimator 815. For a respirator, fit and comfort of wear are dependent on a user’s facial geometry. A mesh applicator 832 may apply a mesh to a detected face in a received image or to a set of facial scan data. The face may be detected using any suitable image analysis technique.

[0151] Landmark detector 830 may generate data regarding distances between landmarks detected from the applied mesh. For example, a distance between two landmarks (e.g., a distance from a detected ground point to a top of head gives a user’s height, or a distance between two detected pupils gives an IPD), or an angle formed by three landmarks may be generated. Other data may be generated. For example, a facial length estimator 834 may generate a facial length estimate, a facial width estimator 836 may generate a facial width estimate, a face seal size estimator 835 may generate a face seal size estimate, a nose portionshape estimator 837 may generate a nose portion shape estimate, and / or a chin portion shape estimator 833 may generate a chin portion shape estimate. Other landmark data may be generated.

[0152] Landmark detector 830 may include machine learning algorithms trained based on relevant training datasets. While it is discussed herein that machine learning algorithms may first detect a series of landmarks and may then generate landmark data based on the detected landmarks, it is expressly contemplated that a machine learning algorithm may, based on the training data, conduct an image comparison between a first scan and a second scan using other methods.

[0153] PPE selecting system 800 may also include a respirator selection system 810. Respirator selection system 810 may include a respirator data retriever 812 which may be configured to retrieve information on one or more respirator models from a respirator database (not shown) . Respirator data retriever may retrieve information relevant to identifying a respirator worn by a user, as well as information regarding fit and comfort score calculation for an identified respirator. A respirator database may include, for example, training data for a machine learning model such as images of individuals with known facial dimensions and fit test results and / or comfort scores.

[0154] A make and / or model of the detected PPE may then be identified by respirator identifier 816. Respirator identifier 816 may analyze images, or other sensor signals that could be used to identify an RPD.

[0155] RPD evaluation system 800 receives information about an RPD user from user information retriever 820. For example, an image receiver 822 may receive an image of a user’s face from a camera or other image source. Other information may be retrieved from another receiver 824, which may receive sensor information, stored data, or other relevant information.

[0156] RPD evaluation system 800 may provide a user with one or more PPE options that may result in a passing fit test score. RPD evaluation system 800 may provide recommendations using a machine learning algorithm, as described in PCT with Application No. PCT / CN2023 / 108870, filed July 24, 2023), or using another suitable method. For example, look-up tables may be used based on identified body dimensions.

[0157] Image information may be used by a fit estimator 814 to generate a likelihood of fit. Fit estimator 814 may be any suitable machine -learning or artificial-intelligence based model. Fit estimator 814 may use processed image analysis from a landmark analyzer 830. However, it is expressly contemplated that fit estimator 814, like other machine learning algorithms herein may, with sufficient training data, generate recommendations based on other image analysis techniques.

[0158] RPD evaluation system 800 may also include a communication component 840 which may communicate a generated selection of one or more PPE models, to another device or to a user interface generator. Communication component 840 may also communicate information from a respirator database which may include relevant donning and doffing instructions and other relevant information for a user 850.

[0159] Respirator selection system 810 may compare the pre-and post PPE donning scan for fit inconsistencies. For example, a respirator fit is dependent on a good seal between the respirator and a user’s face. Fit inconsistencies for a respirator, therefore, may include indications that the seal may leak, or that comfort can be increased - for example by reducing a tightness of one or more RPD straps.

[0160] Fit estimator 814 may calculate a fit factor for a user for a given PPE article. The fit factor may bebased on an image comparison before and after the user dons the PPE article. Fit estimator 814 may include a machine learning algorithm. A fit factor is an alphanumeric indicator of how well, or how poorly, an article of PPE will fit a user. In some embodiments, a fit factor is based on a threshold fit. For respirators, a fit factor of 100 indicates that 1% contaminated air penetration occurred through the respirator body. A fit factor of 1000 indicates 0.1% contaminated air penetration occurred through the respirator body. In some embodiments, a fit factor represents a different measurement of fit likelihood, such as a percentage of an ideal fit, etc.

[0161] RPD evaluation system 800 is illustrated and described as having multiple functional components - selection system 810, user information retriever 820, landmark detector 830, communication component 840, etc. It is expressly contemplated that these functionalities may be completed by one or more algorithms and are described herein separately for ease of understanding. Additionally, it is expressly contemplated that some of functionalities 822-840 are provided by multiple devices. It is also contemplated that not all illustrated functionality is needed in all embodiments. Additionally, some functionalities may be combined.

[0162] RPD evaluation system 800 may also include, or interface with, an augmented reality generator, that may be interactive with a worker, for example as described in related PCT Publication WO 2021 / 229372, published on November 18, 2021, paragraphs [0020-0025] all of which are incorporated herein by reference . A worker may interact with AR generator, for example to view how a given RPD should look when worn, or to adjust a RPD from a current configuration to a preferred configuration. For example, an AR generator may assist a worker in changing a strap placement position.

[0163] RPD evaluation system 800 may also include other functionality 850 as appropriate.

[0164] In some embodiments, the fit analyzer determines the RPD customization instruction by correlating a respirator indication with a user indication to produce a model-specific, dimension-changing directive that meets target fit and comfort criteria. For example, image receiver 822 acquires a contemporaneous facial scan (and, when available, prior records via receiver 824), while respiratory device identifier 816 recognizes the specific respirator and respirator data retriever 812 fetches model-specific specifications and constraints (e.g., modifiable feature geometry, perforation paths or grid coordinates, allowable ranges, and strap force-extension / tension-indicator baselines). User information retriever 820 assembles the user indication from the scan and stored data, after which mesh applicator 832 overlays a facial mesh and landmark detector 830 extracts landmarks. Derived measurements and classifications are produced by facial length estimator 834, facial width estimator 836, face seal size estimator 835, nose portion shape estimator 837, and chin portion shape estimator 833 to form a user fit indication. Fit estimator 814 correlates the respirator indication with the user fit indication to predict sealing performance and computes one or more candidate dimensional deltas (e.g., changes to face-seal aperture area / contour, nose / chin cutout geometry, or strap extension). These deltas are constrained by the retrieved specifications and quantized to the respirator’s available customization primitives (e.g., named outlines, perforation paths, grid coordinates, or tension target tied to the visible indicator), yielding the RPD customization instruction that specifies what feature to modify, where to modify it, and by how much. Communication component 840 delivers the instruction to the user and can prompt a post-donning validation scan to confirm target fit, iterating theadjustment within model constraints if needed.

[0165] FIGS. 9A-9F illustrate an example walkthrough for a user customizing an RPD in accordance with embodiments herein. It is expressly contemplated that objects or features illustrated in FIGS. 9A-9F may be presented differently or in a different combination in some embodiments. Additionally, some embodiments have more, or less, functionality. User interfaces presented in FIGS. 9A-9F are intended to be illustrative of some functionality, and not intended to limit functionality of any embodiments herein.

[0166] FIGS. 9A-9F illustrate an embodiment where a number of user interfaces presented on a mobile computing device 900. However, it is expressly contemplated that other computing devices may be suitable. Additionally, it is expressly contemplated that user interfaces of FIGS. 9A-9F are presented on a display, but functionality described herein is performed by a computing device separate, or even remote from, the display.

[0167] FIG. 9A illustrates a user interface 910 on a device 900, with an indication 912 prompting a user to capture an image without PPE. While FIGS. 9B-9F illustrate an embodiment where a camera is used to capture an image of a user for landmark detection and analysis, it is expressly contemplated that other data capture mechanisms, such as laser scanning, may be used in other embodiments.

[0168] FIG. 9B illustrates a user interface 920 on a device 900 with a captured image 922 presented to a user. A user may have the option to re-take a picture if needed.

[0169] FIG. 9C illustrates a user interface 930 on a device 900 that presents a user with an indication 932 to scan a respirator they wish to customize. In some embodiments, a number of potential RPDs that may fit a user are provided, e.g. in space 934, or elsewhere. The user may also, instead of scanning a barcode or taking an image of an RPD, may user another I / O component, such as a keyboard to type out a model or a scroll bar to select between a number of options. The RPD may also be identified by a user scanning a barcode, entering a model number, searching for a specific model within a database, etc. In some embodiments an image is captured of the respiratory protection device, its packaging, etc., from which a particular model can be identified.

[0170] FIG. 9D illustrates a user interface 940 providing customization instructions 942, and a representative image 944 for a user. The customization instructions 942 are generated based on an analysis of the provided image of the user’s face, and identification of the PPE the user wishes to customize. While FIG. 9D illustrates only one customization instruction, e.g. selecting a face seal size, it is expressly contemplated that a user may be guided through several customization steps - e.g. selecting a nose portion shape and / or a chin portion shape.

[0171] In some embodiments, a user interface may be presented that requests a user to provide an image of the customized RPD. Based on that image, it may be determined whether a user accurately modified the RPD. For example, if a user tore the face shield such that material was moved beyond the “Large” size perimeter, the RPD may no longer provide an adequate fit for the user and the user may be instructed to, for example, discard the tom RPD and select a new RPD for modification.

[0172] Donning and / or doffing instructions may be displayed as well, or in conjunction with selection results.

[0173] FIG. 9F illustrates a user interface 960 presented on a device 900 that illustrates an image of a user wearing a respiratory protection device 962. A user may be prompted to accept the image or may have an option to re-take the image. In some embodiments, an RPD evaluation system may analyze placement of the RPD when worn by a user to determine whether the user needs to make adjustments to improve fit. For example, it may be necessary for the user to adjust strap positions, form a nose portion, etc.

[0174] FIGS. 9G-1 to 9G-3 illustrate an example set of user interfaces 900 that may be presented to a user for modifying a face seal of a disposable respirator to achieve a custom fit. As illustrated in FIG. 9G-1, a user is first instructed to remove a first portion of an aperture. The user interface may include a schematic 972 indicating where a user should remove material and / or an instruction describing where to remove material.

[0175] FIG. 9G-2 illustrates a second user interface that may be presented, indicating a second area 974 that should be removed. FIG. 9G-3 illustrates a third user interface indicating a third area 976 that should be removed.

[0176] While FIGS. 9G-1 to 9G-3 illustrates instructions provided in multiple steps, it is expressly contemplated that a single instruction indicating a final shape may be presented, in some embodiments.

[0177] While FIGS. 9A-9G illustrate an embodiment where a user is customizing a face shield for a disposable respirator, it is expressly contemplated that similar user interfaces may be generated for a user adjusting one or more straps of an RPD. E.g. a user may be prompted to take a side view of their face such that a stretch indicator can be detected.

[0178] RPD evaluation systems described herein may be implemented in a mobile application for an individual user, for example a purchaser of an RPD from a retail store. However, it is also expressly contemplated that RPD evaluation systems described herein may be implemented more broadly across a worksite where a number of workers require PPE for their daily operations.

[0179] For example, RPD evaluation system 800 may be present in a worksite such that workers are prompted to wear an RPD that fits comfortably, which may increase PPE compliance for that worker. A proximity sensor, or camera, may detect a worker approaching a work zone and generate an alert for the worker. The alert may be a visual alert (a blinking or color changing light, for example) or an audio alert (e.g., an alarm, a verbal prompt, etc.).

[0180] Such systems, combined with the ability to customize RPDs to improve fit and / or comfort for a user, may both increase the use of correct PPE, and increase worker comfort.

[0181] Machine learning models described herein can rely on any suitable algorithm, such as a nearest neighbor or other suitable options for generating a selection. It is noted that, without good information about a specific face, it is difficult to determine a fit or comfort metric. A trained machine learning model can learn different relationships between facial measurements and topography that are not as simple as length and width.

[0182] FIG. 10 is a block diagram of a RPD evaluation system architecture. The remote server architecture 1000 illustrates one embodiment of an implementation of a PPE fittest system 1010. As an example, remote server architecture 1000 can provide computation, software, data access, and storage services that do notrequire end-user knowledge of the physical location or configuration of the system that delivers the services. In various embodiments, remote servers can deliver the services over a wide area network, such as the internet, using appropriate protocols. For instance, remote servers can deliver applications over a wide area network, and they can be accessed through a web browser or any other computing component. Software or components shown or described in FIGS. 1-9 as well as the corresponding data, can be stored on servers at a remote location. The computing resources in a remote server environment can be consolidated at a remote data center location or they can be dispersed. Remote server infrastructures can deliver services through shared data centers, even though they appear as a single point of access for the user. Thus, the components and functions described herein can be provided from a remote server at a remote location using a remote server architecture. Alternatively, they can be provided by a conventional server, installed on client devices directly, or in other ways.

[0183] In the example shown in FIG. 10, some items are similar to those shown in earlier figures. FIG. 10 specifically shows that system 1010 can be located at a remote server location 1002. Therefore, computing device 1020 accesses those systems through remote server location 1002. Operator 1050 can use computing device 1020 to access user interfaces 1022 as well. While a single operator 1050 is illustrated as connecting to system 1010, it is expressly contemplated that multiple operators may access system 1010, using either device 1020 or another suitable device.

[0184] FIG. 10 also depicts another example of a remote server architecture. FIG. 10 shows that it is also contemplated that some elements of systems described herein are disposed at remote server location 1002 while others are not. By way of example, storage 1030, 1040 or 1060 can be disposed at a location separate from location 1002 and accessed through the remote server at location 1002. Regardless of where they are located, they can be accessed directly by computing device 1020, through a network (either a wide area network or a local area network), hosted at a remote site by a service, provided as a service, or accessed by a connection service that resides in a remote location. Also, the data can be stored in substantially any location and intermittently accessed by, or forwarded to, interested parties. For instance, physical carriers can be used instead of, or in addition to, electromagnetic wave carriers.

[0185] It will also be noted that the elements of systems described herein, or portions of them, can be disposed on a wide variety of different devices. Some of those devices include servers, desktop computers, laptop computers, imbedded computer, industrial controllers, tablet computers, or other mobile devices, such as palm top computers, cell phones, smart phones, multimedia players, personal digital assistants, etc.

[0186] FIGS. 11-13 show examples of mobile devices that can be used in the embodiments shown in previous Figures.

[0187] FIG. 11 is a simplified block diagram of one illustrative example of a handheld or mobile computing device that can be used as a user's or client's handheld device 1116 (e.g., as computing device 1120 in FIG. 11), in which the present system (or parts of it) can be deployed. For instance, a mobile device can be deployed in the operator compartment of computing device 1120 for use in generating, processing, or displaying the data. FIG. 12 is another example of a handheld or mobile device.

[0188] FIG. 11 provides a general block diagram of the components of a client device 1116 that can run some components shown and described herein. Client device 1116 interacts with them or runs some and interacts with some. In the device 1116, a communications link 1113 is provided that allows the handheld device to communicate with other computing devices and under some embodiments provides a channel for receiving information automatically, such as by scanning. Examples of communications link 1113 include allowing communication though one or more communication protocols, such as wireless services used to provide cellular access to a network, as well as protocols that provide local wireless connections to networks.

[0189] In other examples, applications can be received on a removable Secure Digital (SD) card that is connected to an interface 1115. Interface 1115 and communication links 1113 communicate with a processor 1117 (which can also embody a processor) along a bus 1119 that is also connected to memory 1121 and input / output (I / O) components 1123, as well as clock 1125 and location system 1127.

[0190] I / O components 1123, in one embodiment, are provided to facilitate input and output operations and the device 1116 can include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors and output components such as a display device, a speaker, and or a printer port. Other I / O components 1123 can be used as well.

[0191] Clock 1125 illustratively comprises a real time clock component that outputs a time and date. It can also provide timing functions for processor 1117.

[0192] Illustratively, location system 1127 includes a component that outputs a current geographical location of device 1116. This can include, for instance, a global positioning system (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning system. It can also include, for example, mapping software or navigation software that generates desired maps, navigation routes and other geographic functions.

[0193] Memory 1121 stores operating system 1129, network settings 1131, applications 1133, application configuration settings 1135, data store 1137, communication drivers 1139, and communication configuration settings 1141. Memory 1121 can include all types of tangible volatile and non-volatile computer-readable memory devices. It can also include computer storage media (described below). Memory 1121 stores computer readable instructions that, when executed by processor 1117, cause the processor to perform computer-implemented steps or functions according to the instructions. Processor 1117 can be activated by other components to facilitate their functionality as well.

[0194] FIG. 12 shows that the device can be a smart phone 1271. Smartphone 1271 has a touch sensitive display 1273 that displays icons or tiles or other user input mechanisms 1275. Mechanisms 1275 can be used by a user to run applications, make calls, perform data transfer operations, etc. In general, smart phone 1271 is built on a mobile operating system and offers more advanced computing capability and connectivity than a feature phone.

[0195] Note that other forms of the devices 1271 are possible.

[0196] FIG. 13 is a block diagram of a computing environment that can be used in embodiments shown in previous Figures.

[0197] FIG. 13 is one example of a computing environment in which elements of systems and methods described herein, or parts of them (for example), can be deployed. With reference to FIG. 13, an example system for implementing some embodiments includes a general-purpose computing device in the form of a computer 1310. Components of computer 1310 may include, but are not limited to, a processing unit 1320 (which can comprise a processor), a system memory 1330, and a system bus 1321 that couples various system components including the system memory to the processing unit 1320. The system bus 1321 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. Memory and programs described with respect to systems and methods described herein can be deployed in corresponding portions of FIG. 13.

[0198] Computer 1310 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 1310 and includes both volatile / nonvolatile media and removable / non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media is different from, and does not include, a modulated data signal or carrier wave. It includes hardware storage media including both volatile / nonvolatile and removable / non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information, and which can be accessed by computer 1310. Communication media may embody computer readable instructions, data structures, program modules or other data in a transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0199] The system memory 1330 includes computer storage media in the form of volatile and / or nonvolatile memory such as read only memory (ROM) 1331 and random-access memory (RAM) 1332. A basic input / output system 1333 (BIOS) containing the basic routines that help to transfer information between elements within computer 1310, such as during start-up, is typically stored in ROM 1331. RAM 1332 typically contains data and / or program modules that are immediately accessible to and / or presently being operated on by processing unit 1320. By way of example, and not limitation, FIG. 13 illustrates operating system 1334, application programs 1335, other program modules 1336, and program data 1337.

[0200] The computer 1310 may also include other removable / non-removable and volatile / nonvolatile computer storage media. By way of example only, FIG. 13 illustrates a hard disk drive 1341 that reads from or writes to non-removable, nonvolatile magnetic media, nonvolatile magnetic disk 1352, an optical disk drive 1355, and nonvolatile optical disk 1356. The hard disk drive 1341 is typically connected to the system bus 1321 through a non-removable memory interface such as interface 1340, and optical disk drive 1355 are typically connected to the system bus 1321 by a removable memory interface, such as interface 1350.

[0201] Alternatively, or in addition, the functionality described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include Field-programmable Gate Arrays (FPGAs), Application-specific Integrated Circuits (e.g., ASICs), Application-specific Standard Products (e.g., ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.

[0202] The drives and their associated computer storage media discussed above and illustrated in FIG. 13, provide storage of computer readable instructions, data structures, program modules and other data for the computer 1310. In FIG. 13, for example, hard disk drive 1341 is illustrated as storing operating system 1344, application programs 1345, other program modules 1346, and program data 1347. Note that these components can either be the same as or different from operating system 1334, application programs 1335, other program modules 1336, and program data 1337.

[0203] A user may enter commands and information into the computer 1310 through input devices such as a keyboard 1362, a microphone 1363, and a pointing device 1361, such as a mouse, trackball or touch pad. Other input devices (not shown) may include a joystick, game pad, satellite receiver, scanner, or the like. These and other input devices are often connected to the processing unit 1320 through a user input interface 1360 that is coupled to the system bus but may be connected by other interface and bus structures.A visual display 1391 or other type of display device is also connected to the system bus 1321 via an interface, such as a video interface 1390. In addition to the monitor, computers may also include other peripheral output devices such as speakers 1397 and printer 1396, which may be connected through an output peripheral interface 1395.

[0204] The computer 1310 is operated in a networked environment using logical connections, such as a Local Area Network (LAN) or Wide Area Network (WAN) to one or more remote computers, such as a remote computer 1380.

[0205] When used in a LAN networking environment, the computer 1310 is connected to the LAN 1371 through a network interface or adapter 1370. When used in a WAN networking environment, the computer 1310 typically includes a modem 1372 or other means for establishing communications over the WAN 1373, such as the Internet. In a networked environment, program modules may be stored in a remote memory storage device. FIG. 13 illustrates, for example, that remote application programs 1385 can reside on remote computer 1380.

[0206] A respiratory protection device (RPD) includes a respirator body configured to cover a face of a wearer and a customizable face seal coupled to the perimeter of the respirator body. The face seal has an adjustment feature that, when actuated, adjusts an effective contact area of the customizable face seal with the face of the wearer.

[0207] The RPD may include a customizable face seal that has wrinkled media.

[0208] The RPD may include a respirator body that has wrinkled media.

[0209] The RPD may include an adjustment feature that has a removable area of the face seal.

[0210] The RPD may include a visual indicator for the adjustment feature.

[0211] The visual indicator may include an outline of the removable area.

[0212] The RPD may include a series of removal guides about a perimeter of the removable area.

[0213] The removal guides may include a series of perforations, a series of point bonded points, a series of at least partially melted portions, or a weld line.

[0214] The adjustment feature may include a tear line along the surface of the face seal.

[0215] When tom along the tear line, the effective contact area of the customizable face seal with the face of the wearer may be reduced.

[0216] When the adjustment feature is actuated, the effective contact area of the customizable face seal with the face of the wearer may be reduced.

[0217] The customizable face seal may include a visual indicator.

[0218] The visual indicator may correspond to a face seal size.

[0219] The adjustment feature may be configured to be actuated without the use of tools.

[0220] The face seal may include a nose adjustment feature that, when actuated, adjusts an effective contact area of the customizable face seal with the nose of a wearer.

[0221] The nose adjustment feature may include a removable nose area of the face seal.

[0222] The RPD may include a series of nose removal guides about a nose perimeter of the removable area.

[0223] The removal guides may include a series of perforations, a series of point bonded points, a series of at least partially melted portions, or a weld line.

[0224] The adjustment feature may include a tear line along the surface of the face seal.

[0225] When tom along the tear line, the effective contact area of the customizable face seal with the nose of the wearer may be reduced.

[0226] The face seal may include a chin adjustment feature that, when actuated, adjusts an effective contact area of the customizable face seal with the chin of a wearer.

[0227] The nose adjustment feature may include a removable chin area of the face seal.

[0228] The RPD may include a series of chin removal guides about a chin perimeter of the removable area.

[0229] The removal guides may include a series of perforations, a series of point bonded points, a series of at least partially melted portions, or a weld line.

[0230] The adjustment feature may include a tear line along the surface of the face seal.

[0231] When tom along the tear line, the effective contact area of the customizable face seal with the chin of the wearer may be reduced.

[0232] The RPD may be a disposable respirator.

[0233] The RPD may be a reusable respiratory protection device and may include a headband attached to the main body, with the headband including a strap tension indicator.

[0234] The strap tension indicator may be detectable in the visible light spectmm.

[0235] The strap tension indicator may be detectable in the infrared light spectmm.

[0236] The strap tension indicator may be printed, adhered, bonded, welded, or stitched into the headband.

[0237] The strap tension indicator may include a geometric pattern that changes appearance when the headband is stretched from a resting position to a stretched position.

[0238] The geometric pattern may be configured to indicate a percentage of headband extension.

[0239] The main body may be foldable for compact storage, and the customizable face seal maintains its integrity when the main body is unfolded for use.

[0240] The wrinkled media may include a first series of substantially parallel non-bonded elastic filaments between a first and a second non-woven porous web, where the first non-woven porous web is directly bonded to the second non-woven porous web, and at least one portion of the wrinkled media is resiliently extensible under tension.

[0241] The wrinkled media may include a first series of substantially parallel non-bonded elastic filaments between a first and a second non-woven porous web, where the first non-woven porous web is directly bonded to the second non-woven porous web, and at least one portion of the wrinkled media is resiliently extensible under tension.

[0242] An initial NaCl efficiency of the RPD may be greater than or equal to about 99% at 14 cm / s face velocity.

[0243] An initial NaCl efficiency of the RPD may be greater than or equal to about 98% at 14 cm / s face velocity.

[0244] An initial NaCl efficiency of the RPD may be greater than or equal to about 95% at 14 cm / s face velocity.

[0245] An initial NaCl efficiency of the RPD may be greater than or equal to about 90% at 14 cm / s face velocity.

[0246] A respiratory protection device (RPD) includes a respirator body configured to cover a nose and a mouth of a user and a strap connected to the respirator body. The strap, along with the respirator body, is configured to encircle a head of the user and includes an adjustment mechanism for altering the length of the strap and a tension indicator configured to provide an indication of an amount of extension of the strap.

[0247] The adjustment mechanism may include a buckle.

[0248] The tension indicator may include a visual indicator.

[0249] The visual indicator may include a pattern that elongates in a predictable manner as the strap is stretched.

[0250] The visual indicator may include a first material having a first color and a second material having a second color, with the ratio of the first color to the second color changing based on the tension applied to the strap.

[0251] The strap tension indicator may be detectable in the infrared light spectrum.

[0252] The strap tension indicator may be printed, adhered, bonded, welded, or stitched into the headband.

[0253] The strap tension indicator may include a geometric pattern that changes appearance when the headband is stretched from a resting position to a stretched position.

[0254] The strap may be a first strap configured to be positioned above an ear of a user, and the RPD may include a second strap configured to be positioned below the ear of the user.

[0255] The strap may include an elastic material.

[0256] A method for adjusting the fit of a respiratory protection device (RPD) includes receiving an indication of a type of the RPD using an indication receiver, retrieving a customization option for the RPD based on the type, analyzing a scan of a face of a user of the RPD, determining a customization for the user based on the scan of the face and the retrieved customization option, and providing an instruction for the user for implementing the customization.

[0257] Receiving may include reading a barcode or receiving a user input indicative of the type of the RPD.

[0258] The type may include a model of the RPD.

[0259] The method may be implemented using a device with a computation unit, where the indication receiver includes a camera or a scanning device of the device.

[0260] The customization option may be retrieved from a database of RPD customization options.

[0261] Analyzing may include generating a mesh based on the scan of the face of the user.

[0262] Determining may include detecting a facial landmark.

[0263] The customization may include a size of a face seal of the RPD, with the size detected based on the analysis of the scan of the face of the user.

[0264] The instruction may include a modification instruction for the RPD.

[0265] The modification instruction may include an instruction to remove a portion of the face seal.

[0266] The portion may include a perimeter, with the instruction including an indication to tear the face seal along the perimeter.

[0267] The modification instruction may include an instruction to slit or tear the face seal.

[0268] The customization may include a shape of a nose area of a face seal of the RPD, with the shape of the nose area detected based on the analysis of the scan of the face of the user.

[0269] The instruction may include a modification instruction for the RPD.

[0270] The modification instruction may include an instruction to remove a portion of the face seal in the nose area.

[0271] The face seal may include a nose area portion, with the nose area portion including a nose area perimeter, and the instruction may include an indication to tear the face seal along the nose area perimeter.

[0272] The modification instruction may include an instruction to slit or tear the face seal in the nose area.

[0273] The customization may include a shape of a chin area of a face seal of the RPD, with the shape of the chin area detected based on the analysis of the scan of the face of the user.

[0274] The instruction may include a modification instruction for the RPD.

[0275] The modification instruction may include an instruction to remove a portion of the face seal in the chin area.

[0276] The face seal may include a chin area portion, with the chin area portion including a chin area perimeter, and the instruction may include an indication to tear the face seal along the chin area perimeter.

[0277] The modification instruction may include an instruction to slit or tear the face seal in the chin area.

[0278] The method may include analyzing an image of the face of the user wearing the customized RPD.

[0279] Determining the customization may include detecting an applied force to a head of the user by an adjustable strap of the RPD and determining that the applied force is greater than a minimum applied force. The customization may include an adjustment to a tightness of the adjustable strap.

[0280] Detecting the applied force may include detecting an amount of extension of the adjustable strap and correlating the amount of extension to an applied force using a force -extension curve.

[0281] The indication of the type of the RPD may include a model of the RPD, and the force -extension curve may be retrieved based on the model of the RPD.

[0282] Detecting the applied force may include detecting a tension indication from the scan of the face of the user and, based on the tension indication, calculating the applied force.

[0283] The tension indication may include a visual indication.

[0284] The visual indication may include a geometric pattern or a color.

[0285] The tension indication may be printed, welded, point bonded, or sewn into the adjustable strap.

[0286] The method may include analyzing a second scan of the face of the user after the customization is implemented and detecting a second applied force and determining that the second applied force is sufficient for the RPD to fit the user.

[0287] A respiratory protection device (RPD) fitting system includes a respiratory device identifier configured to identify a respirator, a user information retriever configured to retrieve a user indication, and a fit analyzer configured to retrieve a respirator indication based on the identified respirator, retrieve a user fit indication based on the user facial feature indication, and generate an RPD customization instruction for the respirator. The RPD customization, when implemented, changes a dimension of a respirator feature. The system also includes a communication component configured to communicate the RPD customization instruction to a user.

[0288] The respirator may be a disposable respirator, and the RPD customization instruction may include a face seal size for a user and instructions for modifying a face seal of the respirator, with modifying including permanently deforming the face seal.

[0289] Permanently deforming may include removing material from the face seal.

[0290] Removing material may include increasing a size of an aperture in the face seal.

[0291] Removing material may include tearing or cutting the face seal.

[0292] The RPD fitting system, wherein the fit analyzer generates an RPD customization instruction for the respirator by: (i) receiving the respirator indication comprising an identification of the respirator and linked model-specific specifications and allowable modification constraints; (ii) receiving the user indication comprising at least a user facial feature indication; (iii) deriving a user fit indication by detecting facial landmarks and calculating one or more measurements or shape classifications; (iv) predicting a baseline sealing performance for the identified respirator on the user; (v) computing one or more candidate dimensional changes to a respirator feature, the respirator feature selected from a face seal aperture, a nose portion, a chin portion, or an adjustable strap, the dimensional changes sized to meet a target fit criterion; (vi) enforcing the allowable modification constraints including at least one of: a permissible removal path or grid coordinate, a geometric bound, or a strap force-extension relation; (vii) quantizing the dimensionalchanges to discrete customization primitives associated with the identified respirator including at least one of: a named outline, a perforation or tear path, a coordinate -based removal instruction, or a strap extension / tension target; and (viii) outputting the RPD customization instruction specifying the feature to be modified, a location of the modification, and a magnitude of the modification, and, when the user fit indication indicates strap over-tension, specifying a revised strap extension or tension target.

[0293] The system may include a scanning device configured to scan a face of a user, with the user information retriever identifying the user facial feature indication based on the scan of the face of the user.

[0294] The respiratory device identifier may identify the respirator based on an input from a user, an image of the respirator, or based on a scan of a package of the respirator.

[0295] The user indication may include a facial length, a facial width, a nose shape indication, or a chin shape indication.

[0296] The RPD customization instruction may include a face seal size, a nose portion area, or a chin portion area.

[0297] The dimension may include an area of an aperture in a face seal.

[0298] The communication component may include a user interface generator configured to generate a user interface for display on a device.

[0299] The device may include the RPD fitting system.

[0300] The device may include a camera, with the camera including either the respiratory device identifier or the user information retriever.

[0301] The respirator may include an adjustable strap, and the user fit indication may include a tension indication, with the RPD instruction including a tightness setting for the adjustable strap.

[0302] When the tension indication includes a detected applied force by the strap to a head of the user, the fit analyzer may be further configured to determine that the detected applied force is larger than a minimum applied force, and the RPD customization instruction may include an instruction to loosen the adjustable strap.

[0303] The fit analyzer may be configured to detect the detected applied force based on the tension indication.

[0304] The tension indication may include a geometric pattern.

[0305] The tension indication may include a color.

[0306] The tension indication may be printed, sewn, welded, or point bonded to the adjustable strap.

[0307] The system may include a scanning device configured to capture a first scan data of a user wearing the respirator, and a fit test module configured to detect, using the respiratory device identifier, a model of respirator, retrieve a second scan data of the user not wearing the respirator, compare the first and second scan data using a comparison module, and based on the comparison, generate a fit test result. The system also includes a communication component configured to communicate the generated fit test result to a device with a display.

[0308] The comparison module may be configured to detect, in the second scan data, a plurality of landmarks, generate a plurality of landmark measurements based on the plurality of landmarks, retrieve aspecification associated with the model of respiratory, identify, based on the first scan data, the second scan data, and the specification, a fit inconsistency, and evaluate the fit inconsistency. The fit test result is generated based on the evaluated fit inconsistency.

[0309] The comparison module may include a machine learning algorithm, and the plurality of landmark measurements may include more than 10 landmark measurements.

[0310] The device may be a mobile computing device.

[0311] The received indication may include a barcode scan, an indication from an RFID tag, or an indication from an NFC tag.

[0312] The received indication may include a user input received through an I / O mechanism.

[0313] The respirator may include a disposable respirator, a reusable respirator, or a powered air purifying respirator.

[0314] A method of generating a fit test result for a respiratory protection device (RPD) includes receiving a first scan of a user from a first scanning device, with the first scan including the user without the RPD, identifying a plurality of landmarks on the user based on the first scan, calculating a plurality of landmark measurements for the user based on the scan, receiving a second scan of the user from a second scanning device, with the second scan including the user wearing the RPD, identifying a fit inconsistency for the user, generating, using a fit test results generator, a fit instruction for the user, and communicating the fit instruction for the user.

[0315] The first scanning device may be a camera.

[0316] The first scanning device may be the second scanning device.

[0317] The first scanning device may be at a first location in a worksite, the second scanning device may be at a second location, and the first and second locations may be different.

[0318] The method may include receiving a user input selecting the RPD.

[0319] The method may include detecting a model of the RPD.

[0320] The method may include retrieving a specification for the model of the RPD.

[0321] The device may be a mobile computing device including a display.

[0322] The fit inconsistency may include a face seal size, and the fit instruction may include an instruction to adjust the face seal size, with the second scan of the user captured after the user has adjusted the face seal size.

[0323] Identifying the fit inconsistency may include detecting a facial landmark for the user and, based on the facial landmark and the model of the respirator, determining the face seal size.

[0324] Determining the face seal size may also include detecting a nose portion shape for the user, and the fit instruction may include an instruction to adjust a nose portion of the face seal.

[0325] Determining the face seal size may also include detecting a chin portion shape for the user, and the fit instruction may include an instruction to adjust a chin portion of the face seal.

[0326] Identifying the fit inconsistency may include identifying a tension indicator on an adjustable strap and calculating a tightness of an adjustable strap based on the identified tension indicator, with the tightness higher than a minimum acceptable tightness.

[0327] The tension indicator may include a geometrical pattern, and calculating may include comparing a default geometrical pattern for the adjustable strap with a detected geometrical pattern on the adjustable strap.

[0328] The default geometrical pattern may be retrieved based on an identification of a model of the RPD.

[0329] The tension indicator may include a color, and calculating may include comparing a default color of the adjustable strap with a current color of the adjustable strap.

Claims

WHAT IS CLAIMED IS:

1. A respiratory protection device (RPD) fitting system comprising:a respiratory device identifier configured to identify a respirator;a user information retriever configured to retrieve a user indication;a fit analyzer configured to:retrieve a respirator indication based on the identified respirator;retrieve a user fit indication based on the user facial feature indication; and generate an RPD customization instruction for the respirator, wherein the RPD customization instruction, when implemented, changes a dimension of a respirator feature; anda communication component configured to communicate the RPD customization instruction to a user.

2. The RPD fitting system of claim 1, wherein the respirator comprises a disposable respirator, wherein the RPD customization instruction comprises a face seal size for a user and instructions for modifying a face seal of the respirator, wherein modifying comprises permanently deforming the face seal.

3. The RPD fitting system of claim 2, wherein permanently deforming comprises removing material from the face seal.

4. The RPD fitting system of claim 3, wherein removing material comprises increasing a size of an aperture in the face seal.

5. The RPD fitting system of claim 2, wherein removing material comprises tearing or cutting the face seal.

6. The RPD fitting system of any of claims 1-5, and further comprising:a scanning device configured to scan a face of a user, wherein the user information retriever identifies the user facial feature indication based on the scan of the face of the user.

7. The RPD fitting system of any of claims 1-6, wherein the respiratory device identifier identifies the respirator based on: an input from a user, an image of the respirator, or based on a scan of a package of the respirator.

8. The RPD fitting system of claim 7, wherein the user indication comprises a facial length, a facial width, a nose shape indication, or a chin shape indication.

9. The RPD fitting system of claim 8, wherein the RPD customization instruction comprises a face seal size, a nose portion area or a chin portion area.

10. The RPD fitting system of claim 8, wherein the dimension comprises an area of an aperture in a face seal.

11. The RPD fiting system of any of claims 1-10, wherein the communication component comprises a user interface generator configured to generate a user interface for display on a device.

12. The RPD fiting system of any of claims 1-11, wherein the respirator comprises an adjustable strap, and wherein the user fit indication comprises a tension indication, and wherein the RPD instruction comprises a tightness seting for the adjustable strap.

13. The RPD fiting system of claim 12, wherein, when the tension indication comprises a detected applied force by the strap to a head of the user, wherein the fit analyzer is further configured to determine that the detected applied force is larger than a minimum applied force, and wherein the RPD customization instruction comprises an instruction to loosen the adjustable strap.

14. The RPD fiting system of claim 13, wherein the fit analyzer is configured to detect the detected applied force based on the tension indication.

15. The RPD fiting system of claim 14, wherein the tension indication comprises a geometric patern.

16. The RPD fiting system of claim 14, wherein the tension indication comprises a color.

17. The RPD fiting system of claim 14, wherein the tension indication is printed, sewn, welded, or point bonded to the adjustable strap.

18. The RPD fiting system of any of claims 1-17, and further comprising:a scanning device configured to capture a first scan data of a user wearing the respirator;a fit test module configured to:detect, using the respiratory device identifier, a model of respirator;retrieve a second scan data of the user not wearing the respirator;compare the first and second scan data, using a comparison module; andbased on the comparison, generate a fit test result; anda communication component configured to communicate the generated fit test result to a device with a display.

19. The RPD fiting system of claim 18, wherein the comparison module is configured to: detect, in the second scan data, a plurality of landmarks;generate a plurality of landmark measurements based on the plurality of landmarks; retrieve a specification associated with the model of respiratory;identify, based on the first scan data, the second scan data, and the specification, a fit inconsistency;evaluate the fit inconsistency; andwherein the fit test result is generated based on the evaluated fit inconsistency.

20. The RPD fitting system of claim 19, wherein the comparison module comprises a machine learning algorithm, and wherein plurality of landmark measurements comprises more than 10 landmark measurements.

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