Respirator apparatus

<u>BACKGROUND</u>

00011. <u>Field of the Invention</u>. This invention is directed to personal environmental protection systems, in general, and, more particularly, to a headgear structure which is worn by an individual in an environment wherein control of filtered air and protection from particulate material is required.

00022. <u>Prior Art</u>. There are several types of air flow, filtration and protective systems which are known in the art. Several types of such systems are currently available on the market for use in surgical arenas, in "clean room" environments, or in hazardous/contaminated environments.

0003Some of the existing systems include,hoods, gowns, filters, and the like. In some instances, the air filters are built into the helmet structure and produce a rather clumsy, cumbersome headgear unit. Known units frequently include external sources of air such as gas cylinders, air lines or the like which are connected to the helmet structure by tubes, hoses or the like. The hose-connected systems, and the long gowns or hoods tend to become extremely cumbersome as well as restrictive of the movements and flexibility of the wearer during a procedure.

0004Currently available lens/facial seal combinations, sometimes known as loose fitting hoods, are expensive to manufacture due to the geometries required for the facial seal to attach to the lens which is curved in a plane perpendicular to the seal to the face/head of the wearer.

0005In many of the systems known in the art the hoods and/or gowns are used as filtration devices which have to be replaced frequently. This structure tends, therefore, to become costly inasmuch as the disposable filtration devices are quite expensive.

0006Moreover, these systems tend to be fairly expensive, especially regarding the disposable portions of the system.

0007Many such products are known in the prior art. One suitable and functional system is described in <patcit id="pcit0001" dnum="US5054480A"><text>U.S. Patent No. 5,054,480</text></patcit>; PERSONAL AIR FILTRATION AND CONTROL SYSTEM, R. O. Bare et al.

0008Other such systems are described in <patcit id="pcit0002" dnum="US5711033A"><text>U.S. Patent No. 5,711,033</text></patcit>; AIR FILTRATION AND CONTROL SYSTEM INCLUDING HEADGEAR; L. J. Green, et al, and in <patcit id="pcit0003" dnum="US6918141B"><text>U.S. Patent No. 6,918,141</text></patcit>; PROTECTIVE HEADGEAR SYSTEM; Lawrence J. Green et al.

0009Another related prior disclosure is described in co-pending application PROTECTIVE HEADGEAR SYSTEM WITH FILTER PROTECTION; S.N. <patcit id="pcit0004" dnum="US11442402B"><text>11/442,402; L. J. Green, filed May 30, 2006</text></patcit>.

<u>SUMMARY OF THE INSTANT INVENTION</u>

0010This invention is directed to a protective headgear system which is worn by a surgeon during a surgical procedure, a technician during an assembly process, a worker during handling of toxic wastes, or the like.

0011When using respirators of certain types a protective lens and a facial seal are required. The instant apparatus provides a shield which includes an inexpensive disposable lens and facial seal combination to be used with an appropriate (PAPR) respirator. The system includes a relatively light weight, substantially rigid, support headgear structure.

0012An adjustable headband is attached to the headgear structure for supporting the assembled structure on the wearer's head. An outer, relatively lightweight, substantially rigid filter protector can be provided.

0013The system also includes one or more removable and disposable filters which are adapted to be easily and snugly attached to and supported by the headgear structure to significantly cover the outer surface of the headgear structure.

0014The transparent facial shield including a cuff or facial seal and a flexible lens is adapted to easily attach to the headgear structure so as to cover the face of the wearer in order to maintain sterile, non-contaminating conditions for the wearer.

0015The instant device uses a seal or cuff with a unique configuration which is attached flat to the lens to permit the shield to protect the face and head of the wearer when the lens is bent around the front of the respirator and cuff is pulled into juxtaposition with the wearer's face.

0016In particular, the flexible containment cuff is attached to the lower edge of the lens in order to enclose and provide a sealed space about the wearer's head. The shield (lens and cuff) can be manufactured as a flat, layered device which facilitates production techniques and, thereby, reduces manufacturing costs whereby this facial shield can be a disposable item.

0017A fan mechanism can be incorporated into the helmet system to provide air flow at the headgear structure and a suitable power supply can be used to selectively power the fan, if so desired.

<u>BRIEF DESCRIPTION OF THE DRAWINGS</u>

0018<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Figure 1</figref> is an exploded view of a helmet apparatus with the lens and cuff attachment mounted thereon.</li><li><figref idref="f0002">Figure 2</figref> is a rear view of the apparatus shown in <figref idref="f0001">Figure 1</figref> on a schematic representation of a wearer's head.</li><li><figref idref="f0003">Figure 3</figref> is an oblique view of the apparatus shown in <figref idref="f0001">Figures 1</figref> and <figref idref="f0002">2</figref> without the schematic head.</li><li><figref idref="f0004">Figure 3A</figref> is an enlarged view of a portion of the apparatus shown in <figref idref="f0003">Figure 3</figref>.</li><li><figref idref="f0005">Figure 4</figref> is a frontal view of the apparatus on a schematic representation of a wearer's head.</li><li><figref idref="f0006">Figures 5</figref> is a curvilinear rear view of the lens and cuff attachment shown in <figref idref="f0005">Figure 4</figref> as shaped to conform to the head of a wearer.</li><li><figref idref="f0007">Figure 6</figref> is a curvilinear perspective view of the lens and cuff attachment shown in <figref idref="f0006">Figure 5</figref> without the representative wearer.</li><li><figref idref="f0008">Figure 7</figref> includes <figref idref="f0008">Figures 7A, 7B and 7C</figref> which are front views of additional embodiments of the lens and cuff attachment alone.</li><li><figref idref="f0009">Figure 8</figref> includes <figref idref="f0009">Figures 8A and 8B</figref> wherein, <figref idref="f0009">Figure 8A</figref> is a view of another embodiment of the lens and cuff attachment with an elastic cuff; and</li><li><figref idref="f0009">Figure 8B</figref> is a representation of the combination of the cuff and lens attachment and a protective hood.</li><li><figref idref="f0010">Figure 9</figref> is another embodiment of the cuff and lens attachment with a unitary support structure.</li></ul>

<u>DESCRIPTION OF A PREFERRED EMBODIMENT</u>

0019Concurrent reference is made to <figref idref="f0001 f0002 f0003 f0004">Figures 1 through 3A</figref> which show different views of a preferred embodiment of the invention.

0020Specifically, in <figref idref="f0001">Figure 1</figref> there is shown an exploded view of one embodiment of the helmet and facial shield assembly 10 of the instant invention. The helmet assembly 10 includes the helmet shell 600, the liner 100, the outer filter protector 500, the filter cover support 300, the headband assembly 175 and the facial shield 400 which comprises the lens 401 and the cuff (or seal) 450.

0021The headband 175 is used to seat the helmet 10 on the head of the wearer 500. The headband 175 is fairly conventional and is, also, optional. That is, a different head engaging support mechanism can be utilized or it can be omitted, if preferred.

0022In this illustrative embodiment, the headband 175 includes the head-encircling band 176 which is adjustable to comfortably fit the head size of the individual wearer. The adjustment latch 177 permits the band 176 to be shortened or lengthened in a conventional manner.

0023The band 176 includes suitable attachment arms 179 for attachment to the helmet liner 100 by means of suitable fasteners 180 which can be screws, staples, or the like.

0024The helmet liner 100 is, typically, formed of a lightweight material, such as polypropylene or LDPE, for example. Helmet liner 100 is configured to conform, generally, to the shape of the upper portion of the wearer's head but to be spaced away from the top of the head of the wearer by the appropriate spaces 101 and 102 (see <figref idref="f0003">Figure 3</figref>) which can be formed in the helmet, foam pads or the like.

0025The frontal portion of the liner is designed to span the area between the forehead of the wearer wherein surface 120 acts as the front portion of the headband 175 or is in juxtaposition sufficiently close to minimize airflow therebetween. A surface 130 extends to the outer edge 140 of the liner which may attach to the lower perimeter of the helmet 600, if so desired. The spanning effect may also be accomplished in whole or in part by foam inserts, if so desired.

0026A plurality of holes 150 (seen best in <figref idref="f0003">Figures 3</figref> and <figref idref="f0004">3A</figref>) extend upwardly through the surface 130 of the liner 100 to provide for airflow therethrough and toward the contained volume about the face or the wearer.

0027The liner 100 has an accordion-like area 110 (better seen in <figref idref="f0004">Figure 3A</figref>) which permits the liner 100 to flex and better conform to the wearer's head.

0028In addition, if desired, the liner 100 is sufficiently sturdy to support a cooling or air moving mechanism such as a respirator helmet 600 or the like as known in the prior art. The respirator helmet may be attached to the liner by a snap in groove, 195 around the perimeter of the liner or any other conventional means.

0029A fan covering (not shown) can be joined to or integrally formed to provide a protective and contouring cover for fan mechanism of any conventional type as, for example, described in <patcit id="pcit0005" dnum="USD460584S"><text>U.S. Patent Nos. D460,584</text></patcit> and <patcit id="pcit0006" dnum="US6792944S"><text>6,792,944</text></patcit>. Thus, air flow channels can be defined and maintained around the helmet assembly 10 whereby an optional fan mechanism can provide a cooling and filtered air flow to the wearer of the helmet assembly 10.

0030A filter 700, typically, but not limitatively, fabricated of electrostatically charged fibrous plastic material (e.g., melt blown polypropylene) is configured to conform to the outer shape of the helmet shell 600 and is adapted to fit fairly snugly thereto. Features as described in <patcit id="pcit0007" dnum="US6918141B"><text>US Patent No. 6,918,141</text></patcit> (noted supra) support the filter and create an air channel beneath it. Alternately, the filter may be so designed as to be self supporting. The level or degree of filtration of air which enters or leaves the helmet shell 600 can be controlled by appropriate selection of the material of the filter 700,

0031Filter 700 is, typically, mounted to the helmet shell 600 with a force friction fit and by snaps around the perimeter of the helmet as illustrated by side and rear snaps 710 and 711. Of course, any suitable fastener can be utilized. As will be described infra, the top edge of lens 400 is attached to the perimeter of the helmet shell 600, the liner 100, or the filter cover support 300, if so equipped.

0032In this embodiment, a filter protector 500 is provided to cover the filter 700. The filter protector 500 can be fabricated of a material which is the same as (or similar to) helmet liner 100, if so desired. The filter protector 500 prevents damage to the filter 700 and, as well, prevents persons (including the helmet wearer) from touching the possibly contaminated surface of filter 700. The filter protector 500 is attached to the helmet shell 100, typically, by a force-fit or any other technique.

0033The rear deck (or tail) 187 of the helmet liner 100 engages the rear edge of helmet 600 and provides additional stability to the apparatus.

0034A facial lens 401 fabricated of an impermeable, flexible and transparent material such as polycarbonate, or the like, is adapted to be mounted to and bear against the outer front surface of filter cover support, as described infra. The juxtaposition of the inner surface of the lens 401 and the outer surface of the filter cover support provides a seal therebetween. A sealing means 410 as described infra or other suitable means may be provided to enhance the seal.

0035The cuff 450 is fabricated of a sheet of pliant material such as rayon or thin plastic or meltblown polypropylene. The cuff 450 also serves as a protective barrier to prevent particulate material from being transmitted to or from the wearer to or from the ambient.

0036The cuff 450 is attached to the lens 401 along a seam 425. The mid-portion of cuff 450 is adapted to be tucked under the chin of the wearer.

0037Referring now to <figref idref="f0004">Figure 3A</figref>, there is shown an enlarged view of a portion of the view of the apparatus shown in <figref idref="f0003">Figure 3</figref>. This enlarged view shows the arrangement of the holes 150, and the accordion-like area 110.

0038Also, the interaction of the shield 400, the liner 100, and the support tabs 451 and 452 is shown in greater detail.

0039Notably, the upper edges 456 and 457, respectively, of support tabs 452 and 453 are held in close proximity to the extension of liner surface 130. Likewise, the support tabs maintain the upper extensions 461 and 462 of cuff free edge 451 in close proximity to the wearer's head, as better seen in <figref idref="f0006">Figure 5</figref>.

0040Thus, it is contemplated that facial shield 400 comprising lens 401 and protective cuff 450 can be joined together as a subassembly and placed over the helmet shell 600, in concert with liner 100 or spanning means to define an enclosed volume about the face of the wearer thereby providing or enhancing the filtering and protecting functions described.

0041The M-shaped cuff 450 includes the enlarged portion 460 at the mid-portion thereof. This "bump" or "nose" portion is provided in order to provide a secure engagement under and with the chin of the wearer of the helmet.

0042Suitable connectors (or attachments) 403, 404 and 405, such as sections of hook-and-loop material, holes for engaging snap posts or an adhesive strip may be applied near the upper edge 402 of lens 401. These connectors (or adhesive strip) can be used to attach the upper edge 402 of lens 401 to the front of the helmet liner 100, helmet 600 or filter protector support 300 (see <figref idref="f0001">Figures 1</figref> and <figref idref="f0005">4</figref>).

0043In some embodiments it may be desirable to have a strip 410 of sealing material such as foam, a rubber tube or other compressible strip which can engage the front of the liner 100 or helmet 600 providing an enhanced seal thereto.

0044In a preferred embodiment the seal is a thin strip 410 of pretensioned elastic applied flat to lens 401 and adhered along one side to create a fixed edge 412 and a free edge 411 such that when the lens 401 is bent the free edge 411 will seek a smaller radius of curvature, with an arc length closer to its untensioned length, than the fixed edge 412. This causes the surface 413 to tend toward perpendicular to the surface of lens 401. Thus an inexpensive gasket is produced with a spanning capability equivalent to the width of surface 413.

0045Referring now to <figref idref="f0005">Figures 4</figref>, <figref idref="f0006">5</figref> and <figref idref="f0007">6</figref>, there is shown a typical application of the lens/cuff assembly. (The helmet 10 is omitted from <figref idref="f0006">Figures 5</figref> and <figref idref="f0007">6</figref> for clarity of description. Moreover, the shield 400 can be used with many types and shapes of helmets which incorporate a suitable connector or attachment mechanism.)

0046As seen, the cuff 450 is separated from the lens 401 (except at the joinder edge 425). Concurrently, the lens 401 is curved into a generally semi-circular configuration to surround the wearer's head.

0047The connectors 403 and 404 ((a similar connection 405 is seen in <figref idref="f0007">Figure 6</figref>) are attached to a counterpart connector on the front of the filter cover support 300 (not shown). Thus, the lens 401 assumes a curvilinear configuration in front of the face to the wearer 590 of the helmet.

0048At the same time, the cuff 450, in particular the nose 460 (see <figref idref="f0008">Figures 7A, 7B and 7C</figref>) is placed under the chin of the wearer 590 to enhance the gripping of the chin by the cuff and the protection provided thereby. The edge 451 of the cuff 450 otherwise engages the neck and throat area of the wearer 590, as best seen in <figref idref="f0006">Figure 5</figref>. The cuff 450 also engages the sides of the head of the wearer 590 and forms a protective surface therearound.

0049The flexible support tabs 452 and 453 are arranged to cause the cuff 450 to maintain the preferred shape surrounding the head of the wearer 500, as described supra. Specifically they interact with the tension created along the edge 451 by the insertion of the wearers face to draw the upper extension of the free edge 462 (and similarly 461 shown in <figref idref="f0007">Figure 6</figref>) into contact or close proximity of the temple area of the wearers head thus extending away from the joinder edge 425 into abutment with the upper or temporal portion of the head of the wearer 590.

0050The optional slots 454 and 455 are provided to accept and engage a portion of the edge of the helmet liner 100, if desired.

0051In <figref idref="f0007">Figure 6</figref>, there is shown a perspective view of the lens and cuff attachment to be used with the helmet shell 100 shown in prior <figref idref="f0001">Figures 1</figref>, <figref idref="f0002">2</figref> and <figref idref="f0003">3</figref>.

0052As described supra, the lens 401 is fabricated of a thin sheet of transparent polycarbonate (or similar) plastic. A suitable thickness is about 0.01 inches thick although thicker or thinner materials may be used.

0053The cuff 450 is fabricated of a suitably supple material such as but not limited to rayon, meltblown polypropylene, latex rubber or the like and is about 0.01 inches thick dependant on the characteristics of the material.

0054The lens 401 and cuff 450 are joined together at the curved edge 425 by any suitable means such as gluing, stitching or the like.

0055The free edge 402 of lens 401 is shaped to properly mate with the front edge of the helmet liner 100 and/or filter protector support 300, as described supra.

0056The free edge of the cuff 451, in a preferred embodiment, is formed in an undulating, generally, M-shape with nose 460, better seen in <figref idref="f0008">Figures 7A, 7B and 7C</figref>.

0057Support tabs 452 and 453 can be provided at the upper ends of the cuff 450 adjacent to the respective ends of the curved end 425. The support tabs permit advantageous fitting of the cuff to helmet. Typically, the tabs 452 and 453 are flexible about an axis parallel to the flat surface of the tab but less so in other directions.

0058In some embodiments, it is desirable to provide the slits 454 and 455 for engaging the edges of the helmet liner 100.

0059Referring concurrently now to <figref idref="f0008">Figure 7</figref>, and particularly to <figref idref="f0008">Figures 7A, 7B and 7C</figref>, there are shown additional embodiments of the shield combination 400 of lens 401 and cuff 450. <figref idref="f0008">Figures 7A, 7B and 7C</figref> demonstrate the ability of these devices to be manufactured in a flat or two-dimensional configuration which is more easily achieved with automated production equipment.

0060In <figref idref="f0008">Figure 7A</figref>, the lens 401 includes an adhesive band 408 attached at the upper edge thereof. The adhesive band 408 replaces the hook-and-loop connectors 402, 403 and 405, holes 402A, 403A and 405A or other features are used to assist in alignment. The adhesive band 408 can be a multiple use adhesive for re-adhering the shield to the helmet, if desired. Typically, the adhesive band 408 is a tacky material so that the shield 400 can be removed from the helmet and discarded after use.

0061In this embodiment, the flexible supports 452 and 453 include the slots 454 and 455 therein. In addition, flexible gores 406 and 407 are included between the ends of the cuff 450 and the supports 452 and 452, respectively. The flexible gores permit some stretchability or elasticity in the structure of cuff 450. The gores can be fabricated of any suitable stretchable material such as spandex or latex rubber.

0062In <figref idref="f0008">Figure 7B</figref>, there is shown another embodiment of the shield 400. In this embodiment, the lens 401, similar to the lens 401 in <figref idref="f0008">Figure 7A</figref> in that it includes an adhesive band 408 and/or attachment features 402, 403 and 405 at the edge thereof. The nose 460 is provided along the free edge 451 of the cuff 450 .

0063In the embodiment shown in <figref idref="f0008">Figure 7B</figref>, the cuff 450A has elongated end portions 470 and 471 which extend beyond the edge 402 and band 408 of the lens 401. An elastic band (or cord) 480 is affixed to the ends 470 and 471 in any suitable fashion.

0064The elastic band 480 can be stretched to pass over the helmet, head and/or nape of the neck of the wearer and then contract to form a reasonably snug but comfortable fit of the cuff 450A to the wearer. This structure allows the entire cuff to be made of a less expensive non-stretchable material such as SMS polypropylene or a cellulose non-woven. Alternatively, a tie, drawstring or other securing means can be used to secure the helmet/shield apparatus to the wearer. The lens 401 and cuff 450, thus, provide a protective barrier for the face of the wearer.

0065In <figref idref="f0008">Figure 7C</figref>, there is shown another embodiment of the shield 400. In this embodiment, the lens 401 and adhesive band 408 are similar to those shown in <figref idref="f0008">Figure 7B</figref>. Likewise, the cuff 450A with the elongated ends 470 and 471 is shown.

0066However, in this embodiment, the ends 470 and 471 include openings 490 and 491, respectively therethrough.

0067In this case, the openings (or holes) 490 and 491 can be utilized to engage suitable mounting devices, such as knob 115 shown on the helmet liner 100 in <figref idref="f0003">Figure 3</figref>.

0068Alternatively, a cord, elastic band, or other suitable securing components attached to helmet liner 100 can be utilized, as well.

0069Referring now to <figref idref="f0009">Figure 8</figref>, particularly the embodiment shown in <figref idref="f0009">Figure 8A</figref>, the entire cuff 450B can be made of an extremely stretchable material with an elasticity of greater than 300%, such as latex or silicone rubber. In this structure the free edge of the cuff 450B can assume any shape. The support tabs 452 and 453 or features similar to 612 and 613 or 610, 611 and 620 would provide means to draw the free edge into communication with the wearers head. As these materials tend to be expensive or uncomfortable against the wearers face this is considered less desirable.

0070Referring to <figref idref="f0009">Figure 8B</figref>, the lens and cuff assembly 400 may be attached to a hood 800 such as is described in <patcit id="pcit0008" dnum="US5054480A"><text>US Patent No. 5,054,480; Bare, et al</text></patcit> noted supra. The hood 800 is designed for use with a similar helmet structure as previously described. Within the hood 800, the cuff 450 defines a smaller space volume about the face of the wearer which is being easier to restrict contaminant entry thereto.

0071In this configuration, the filter protector 300 as described supra is omitted and the hood 800 encloses the wearer's head, as well as the helmet. At least a portion 810 of the hood can be constructed of a permeable material such as open cell foam, felt or meltblown polypropylene so as to provide airflow therethrough and into filter 600 (see <figref idref="f0001">Figure 1</figref>).

0072If desired, the permeable portion 810 may be constructed of an electrostatically charged meltblown polypropylene or other filter media thereby acting as a prefilter for filter 600, or in some instances as a filter in lieu of filter 600.

0073Referring now to <figref idref="f0010">Figure 9</figref>, the lens and cuff assembly 400 may be attached to a support structure allowing it to form the contained volume about the wearers face with out requiring a ridged supporting structure or helmet.

0074In this configuration, lens 400 is similar to previous configurations in that cuff 450C is attached to lens 401 about edge 425, the free edge 451 of cuff 450C contains nose 460, support tabs 452 and 453 and stretchable gores 406 and 407 are included, if so desired.

0075An extension 941 to cuff 450C has free edge 947 extending from edge 451 to create a closed profile which encircles the wearer's head. Headband 920 is attached to free edge 947 at joinders 946 and 947 by sewing or other conventional means. This arrangement causes the headband to rest against the wearer's forehead thereby stabilizing the hood on the wearer's head. A second strap 925 is installed to extend across the top of the wearer's head, if desired.

0076A second ply 940 of material is attached to the upper edge 402 of lens 401. The second ply is attached to cuff extension 941 along edge 945 by sewing or other conventional means to create a contained volume about the wearers face and head, if desired.

0077An opening 950 is provided in cuff extension 942 for attachment of an air supply means.

0078Referring again to <figref idref="f0008">Figures 7A, 7B, 7C</figref> and <figref idref="f0010">9</figref>, the areas 470A respectively, adjacent to the free edge 451 of the cuff 450 may be cut in a pattern of interlocking lines (or strips) which will allow some give or stretch in a normally non-stretchable material such as SMS meltblown polypropylene, cellulose non-woven, or the like as described supra. The elastic recovery capability of this patterned area may be enhanced by the adhesion of elastic fibers of hot melt adhesive or the like, if so desired.

0079Thus, there is shown and described a unique design and concept of a respirator apparatus. While this description is directed to particular embodiments, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiments shown and described herein. Any such modifications or variations which are within the purview of this description are intended to be included therein as well. It is understood that the description herein is intended to be illustrative only and is not intended to be limitative. Rather, the scope of the invention described herein is limited only by the claims appended hereto.