IMPROVEMENTS IN AIR DELIVERY DEVICES

Abstract

A respirator comprising: an air supply unit arranged to deliver air at its output; headgear comprising a cradle for interfacing with a user's head, and a face covering from within which the user breathes; a tube to receive air from the air supply unit; and an interface component to receive aft from the tube and to deliver said air within the face covering. Components of the respirator and related methods are also described.

Claims

1. A respirator comprising: an air supply unit arranged to deliver air at its output; headgear comprising a cradle for interfacing with a user's head, and a face covering from within which the user breathes; a tube to receive air from the air supply unit; and an interface component to receive air from the tube and to deliver said air within the face covering.

2. The respirator of claim 1, wherein the interface component is releasably mounted to one, two or three of: the cradle; the tube; and the face covering.

3. The respirator of claim 1, wherein the cradle comprises an adjuster that cooperates with a cradle-engaging fastening of the interface component to mount the interface component to the cradle.

4. The respirator of claim 3, wherein the cradle-engaging fastening comprises a bracket that connects between the adjuster of a cradle and the interface component.

5. The respirator of claim 1 wherein the interface component provides a frame for supporting the face covering, and comprises an overhead branch and a forehead branch.

6. The respirator of claim 5, wherein the forehead branch comprises an outwardly-projecting brim, with face covering fastenings extending therefrom.

7. The respirator of claim 5, wherein the overhead branch comprises an internal conduit, to receive air from the tube at the rear the user's head and to deliver said air to the front of the user's head, passing over the user's head user in the headgear.

8. The respirator of claim 5, wherein the overhead branch comprises a generally flattened internal cross-section toward the centre thereof

9. The respirator of claim 5, wherein the overhead branch comprises a divergent portion to feed air to the forehead branch.

10. The respirator of claim 5, wherein the forehead branch comprises a vent arranged to deliver airflow over the face of the user in a generally downward direction, from in front and above the face of the user.

11. The respirator of claim 10, wherein the forehead branch comprises a vent that is generally divergent toward its open end.

12. The respirator of claim 10, wherein the forehead branch comprises a vent with a bevelled edge, the bevel providing a local divergence toward the open end of the vent.

13. The respirator of claim 5, wherein the interface component mounts to the tube such that the tube approaches the interface component in a direction generally parallel to a user's back, aligned with a rising part of the overhead branch of the interface component.

14. The respirator of claim 5, wherein the overhead branch comprises one or more bleed holes, such that in use vibrations from the air supply and tube are reduced.

15. The respirator of claim 1, comprising a vibration decoupler, provided between the air supply unit and the interface component.

16. A respirator, comprising: an air supply unit arranged to deliver air at its output; headgear comprising a cradle for interfacing with a user's head, and a face covering from within which the user breathes; a tube to receive air from the air supply unit; and an interface component to receive air from the tube and to deliver said air within the face covering, wherein the interface component provides a frame for supporting the face covering, and comprises an overhead branch and a forehead branch, wherein the overhead branch comprises a divergent portion to feed air to the forehead branch, to provide a curtain of air between the face covering and the users eyes, nose and mouth.

17. The respirator of claim 16, wherein the overhead branch comprises an internal conduit to receive air from the tube, and the divergent portion is fan-shaped.

18. The respirator of claim 17, wherein the forehead branch comprises a vent with a bevelled edge, the bevel providing a local divergence toward the open end of the vent.

19. A respirator comprising: an air supply unit arranged to deliver air at its output; headgear comprising a cradle configured to interface with a user's head, and a face covering; a tube to receive air from the air supply unit; and an interface component to receive air from the tube and to deliver said air within the face covering.

20. The respirator of claim 19, comprising a vibration decoupler, provided between the air supply unit and the interface component.

Description

BRIEF INTRODUCTION TO THE FIGURES

[0127] For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

[0128] FIG. 1 shows a schematic overview of a respirator according to an example embodiment;

[0129] FIG. 2 shows an intermediate component according to an example embodiment, viewed from above;

[0130] FIG. 3 shows the intermediate component of FIG. 2, viewed from a first side;

[0131] FIG. 4 shows the intermediate component of FIG. 2, viewed from a second side;

[0132] FIG. 5 shows the intermediate component of FIG. 2, viewed from the front;

[0133] FIG. 6 shows the intermediate component of FIG. 2, viewed from the rear;

[0134] FIG. 7 shows the intermediate component of FIG. 2, viewed from below;

[0135] FIG. 8 shows an intermediate component according to another example embodiment, viewed from a first side;

[0136] FIG. 9 shows the intermediate component of FIG. 8, viewed from the front;

[0137] FIG. 10 shows the intermediate component of FIG. 8, viewed from the rear;

[0138] FIG. 11 shows the closeup schematic of the intermediate component of FIG. 8 centred on a vibration decoupler thereof;

[0139] FIG. 12 shows first and second example vibration decoupler tubes, for use in a vibration decoupler according to an example embodiment;

[0140] FIG. 13 shows the second example vibration decoupler according to an example embodiment, in use with headgear of a respirator;

[0141] FIG. 14 shows a partial sectional view revealing interior detail of the intermediate component of FIG. 2;

[0142] FIG. 15 shows a partial view of the rear, underside aspect of the overhead branch of the intermediate component of FIG. 2;

[0143] FIG. 16 shows a partial close-up view of the overheard branch of the intermediate component of FIG. 2

[0144] FIG. 17 shows a partial close-up perspective view of the forehead branch of the intermediate component of FIG. 2

[0145] FIG. 18 shows a side view of an intermediate component according to another example embodiment mounted on a cradle;

[0146] FIG. 19 shows a partial front view of the intermediate component of FIG. 18 mounted on a cradle;

[0147] FIG. 20 shows an intermediate component including a bracket; and

[0148] FIG. 21 shows a respirator according to another example embodiment.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0149] Referring now to FIG. 1 there is shown a respirator 1. The respirator 1 comprises an air supply unit 2. The air supply unit 2 comprises a battery-powered air blower, fitted with an internal filter so that it in use atmospheric air is taken in by the air supply unit, and delivered at increased pressure to flow from the air supply unit's output 3. The air supply unit 2 mounts to a belt 5 to be conveniently worn on the body of a user of the respirator 1. The respirator 1 comprises powered air-purifying respirator type.

[0150] Air from the outlet 3 of the air supply unit 2 is received by a tube 4. An interface component cooperates 100 with headgear 200 to deliver air that is received from the tube 4 to the user of the respirator 1, for breathing by the user. The interface component 100 comprises an internal conduit through which air from the tube 4 at the rear the user's head passes, to be delivered to the front of the user's head, within the headgear 200.

[0151] The headgear 200 comprises a cradle 210 for interfacing with a user's head, and by which the headgear 200 is supported in use. The headgear 200 also comprises a face covering 220 from within which the user breathes. The face covering 220 comprises a fabric hood 221, and a transparent visor portion 222 for the user the user to see through. The interface component 100 is coupled to the tube 4, receives air from the tube 4 and delivers said air within the face covering 220. As can be appreciated from the shape, the interface component 100 locates over the user's head in use, within the hood 221.

[0152] The interface component 100 by which air is delivered within the face covering 220 enables enhanced ergonomics for the headgear 200 and as a consequence for the respirator 1 overall. In the example embodiment of FIG. 1, the tube 4 and cradle 210 are not integral or otherwise directly connected with one another, instead being connected structurally and for air delivery via the interface component 100. Such construction means that these components can be separately specified for a range of different potential users of the respirator 1, such as users having different face and head proportions, facilitating manufacture. As the interface component 100 does not touch or otherwise directly engage the user, a single component can be produced which cooperates with headgear formed of cradle 210 and face covering 220 of different sizes for different potential users, with a consistent interface provided for the tube 4.

[0153] Features of the interface component 100 enable the interface component 100 of FIGS. 2 through 7 to be mounted to the cradle 210 and tube 4 in a releasable manner.

[0154] Referring now to FIGS. 2 through 7 and 18 through 20, the interface component 100 comprises cradle-engaging fastenings 110, 112, 114. The interface component 100 and cradle 210 each comprise portions of releasable and re-couplable fastenings that in use to cooperate with each other to mount the interface component 100 to the cradle 210, as described in more detail below.

[0155] The cradle 210 comprises threaded bars 211 that extend radially away from the user's head, in this example from the area of the user's temples. The threaded bars 211 are either integral with the cradle 210, or are provided by separate bolts that thread through the cradle 210 and engage suitable footings in the cradle 210. The cradle-engaging fastenings 110, 112 are threaded onto the bars 211 and nuts 212 provided to clamp the cradle 210 and interface component 100 to one another. A secure, yet releasable fastening is thus provided. The fastening is stable, with connections at either side of the cradle 210, and resistant to relative rotation as the surfaces of the cradle-engaging fastenings 110, 112 and the interface component abut one another.

[0156] Further stability is provided by the cradle-engaging fastening 114 at the rear of the interface component 100. The cradle 210 comprises a size adjuster 216 for changing its effective circumference, to enable a good fit on a range of different head sizes. The cradle-engaging fastening 114 of the interface component 100 mounts the interface component to the cradle 210 at the size adjuster 216, giving a three-point connection between the components. The cradle engaging-fastening 114 comprises an abutment which accepts a bracket 116. The bracket 116 connects between the size adjuster 216 of the cradle 210 and cradle-engaging fastening 114 at the rear of the interface component 100, as a 90-degree angle bracket held in place vertically by the abutment of the cradle-engaging fastening 114 and for example by a friction fit with said abutment horizontally.

[0157] The interface component 100 comprises a frame for supporting the face covering 220. The interface component 100 comprises an overhead branch 130 and a forehead branch 140. The interface component 100 is releasably mounted to the lace covering 220 by face covering fastenings 118, 120 that couple the interface component to the face covering 220. The face covering fastenings 118 are provided as fixing bosses extending from the forehead branch 140 of the interface component 100, and in use cooperate with the face covering by a button-like action to be releasable and re-couplable. The position of the face covering fastenings 118 at the outward edge of an outwardly-projecting brim 141 of the forehead branch 140 serves to maintain effective spacing between the face covering 220 and the user's face.

[0158] As described in more detail below, the tube 4 is either releasably connected to the interface component at tube fastenings elements 150 of the interface component 100, or to interface component 110 and the face covering 220 in a combined connection 120, 150. The interface component 110 and tube 4 comprise separately or together releasable and re-couplable fastening elements 150 that cooperate to releasably mount the interface component 110 to the tube 4, and optionally to the face covering 220.

[0159] The overhead branch 130 comprises a single main air conduit therethrough, with internal cross-section that narrows from the rear, toward the front, along part of its length. In this narrowing portion 131, flow accelerates through the conduit, for better delivery from the forehead branch, as will be described later. The shape of the central part of the overhead branch 130, which comprises a generally flattened internal and external cross-section, reduces the overhead clearance needed for the respirator. The shaping of overhead branch 130 also services to quieten the flow of air through the conduit avoiding abrupt pressure changes associated with sharp bends and changes in cross section. The narrowing portion 131 may transition along its length so as to narrow in the vertical direction, with a corresponding smaller increase in width in another direction, such as the horizontal direction to achieve a suitable reduction in overall cross-sectional area

[0160] To further reduce the noise of air moving through and discharging from the interface component 100, bleed holes 135 are provided in the narrowing portion 131 of the overhead branch 130. In the examples show in the Figures, the bleed holes 135 open toward the user's head. The bleed holes 135 reduce pressure in the interface component 100, and provide cooling air flow to the top of the user's head. The bleed holes 135, and the movement of air therethrough and over their apertures serves to change the general flow pattern of air passing through the narrowing portion 131 of the overhead branch 130 to further reduce noise. The bleed holes 135 are angled to pass through the wall of the narrowing portion 131 of the overhead branch 130 with the airflow therethrough making an acute angle to the direction of airflow in the overhead branch 130. This arrangement has been found to be particularly effective in reducing noise. Bleed holes with a cross section of around 3 mm diameter have been found effective in reducing noise, for typical flow rates expected in a respirator as described.

[0161] Delivery of air from the interface component 100 takes place by diverging the flow in a divergent portion 132 of the overhead branch 130. The divergent portion 132 is arranged to feed air to the forehead branch 140. In the embodiments shown, the overhead branch 130 comprises a divergent portion 132 which is fan-shaped. The divergent portion 132 is divergent in the width direction, but may conveniently be of constant height away from the head to maintain clearance, and further curved around the contour of the forehead to match the curve of the forehead branch 140. The forehead branch 140 comprises a vent 142 for delivery of air from the interface component 100 within the face covering 220. In the embodiments shown in the Figures a single vent 142 that is relatively wide is provided, in order to facilitate discharge therefrom.

[0162] The vent 142 is generally divergent toward its open end, and comprises at its extremity a bevelled edge 143. The bevelled edge 143 provides a further degree of local divergence at the edge of the vent 142, at the interface with the brim 141 of the forehead branch 140. The divergence toward the open end of the vent, both large and small on account of the general shape and the bevelled edge respectively, services to control discharge from the vent 142 to produce quiet operation, and to avoid a potentially irritating direct curtain of air impinging on the user's face.

[0163] In the examples shown in the Figures, the interface component 100 is mounted to the tube 4 such that the tube 4 approaches the interface component 100 in a vertically upward direction, generally parallel to the user's back. In this configuration, in embodiment with air supply unit 2 mounted to a belt 5, the tube 4 is conveniently routed to directly approaches the interface component 100, and to align and connection generally co-linearly with a rising part 136 of the overhead branch 130 of the interface component 100. By providing an interface at a rising part 136 of the overhead branch 130, the tube 4 increased user comfort may be experienced, as the weight of the tube 4 acts on the headgear 200 with minimal additional turning moment from a horizontally extending part of the tube that would otherwise project away from the user's head and produce a torque thereon due to its weight.

[0164] FIGS. 8 through 13 and 20 show an example respirator 1 that comprises a vibration decoupler 160, 160′, or show component elements thereof. Vibrations arise in the tube 4 because of the action of the air supply unit 2, and/or from the action of movement of air within the tube 4. The vibration decoupler 160 is provided between the air supply unit 2 and the interface component 110. By providing a vibration decoupler, vibration from the air supply unit 2 and/or tube 4 is not passed through the respirator to the user, meaning that the respirator is quieter for the user.

[0165] In the examples shown, the vibration decoupler 160 is provided between the tube 4 and the interface component 110, as a convenient position to decouple the interface component 100 from vibrations passing along the tube 4.

[0166] The vibration decoupler 160 comprises a thin, pliable fabric tube, formed from a flat pattern piece. FIG. 12 shows two vibration decouplers 160, 160′, flattened to form the shape of a parallelogram and a rectangle respectively. The vibration decouplers 160, 160′ are respectively formed by welding a seam along the edges of a pattern piece, and by sewing the edges of a pattern piece.

[0167] The vibration decoupler 160, comprises offset first and second open ends. As shown in FIG. 13, this enables a vertical arrangement of the tube 4 as it interfaces the interface component 100 at the tube fastening 150, and continuing up through the vibration decoupler to the interface component 110, but with a lateral offset to keep the tube 4 in an ergonomic arrangement away from the user's neck without requiring the tube 4 to bend. As shown schematically in FIG. 11, the vibration decoupler 160′ comprises an internal spacer 161 to prevent collapse thereof. The spacer 161 is internal to the tube of the vibration decoupler 160′, and is coupled thereto without bridging contact across the tube 4 and the interface component 100.

[0168] The respirator 1 is suitable for use in method of assembly where a relatively smaller range of headgear size options, such as a range that comprises only a large size hood and a small sized hood, can be made to work effectively for the majority of users by specifying an adjustable cradle, and by specifying an interface component that is either personally sized and manufactured by ALM or similar, or from a range of sizes with finer granularity.

[0169] As has been described herein, the respirator and associated methods offer a range of wearability enhancements, considering noise and other ergonomic factors, and are flexible to be readily adapted to users of different proportions and sizes, as well as accommodating different cleaning and other serviceability factors required for respirator components.

[0170] Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

[0171] Attention is directed to all papers and documents which are filed concurrently with or before this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0172] All the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0173] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0174] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.