Patent Description:
Respiratory protection devices commonly include a mask body and one or more filter cartridges that are attached to the mask body. The mask body is worn on a person's face, over the nose and mouth, and may include portions that cover the head, neck, or other body parts in some cases. Clean air is made available to a wearer after passing through filter media disposed in the filter cartridge. In negative pressure respiratory protection devices, air is drawn through a filter cartridge by a negative pressure generated by a wearer during inhalation. In powered air devices, a fan or other powered unit may assist in delivering air to a user. Air from the external environment passes through the filter medium and enters an interior space of the mask body where it may be inhaled by the wearer.

Various techniques have been used to attach filter cartridges or elements to a respirator. Filter cartridges are commonly connected to an inlet port of a mask body via a threaded engagement, bayonet engagement, or other engagement, for example. In the case of dual cartridge respiratory protection devices, in which two cartridges are provided to filter air for a wearer, the filter cartridges are often connected to air inlets located proximate each cheek portion of the mask, away from a central portion of the mask, such that the cartridges extend outward at sides of the wearer's head. Inhalation check valves are commonly provided for each air inlet, such that air may be delivered from the filter cartridge into the breathing zone through the air inlet away from a central portion, and proximate each cheek portion of the mask body for example.

<CIT> describes a respirator mask, including a unitary body member formed of a flexible rubberlike material and having an inner surface to fit and seal upon the face of a user, wherein the body member including at least one opening to receive a filter cartridge and including an internally extending flange portion forming the circumference of the opening. The filter cartridge is formed of a substantially rigid material and includes an inner grooved portion having a shape substantially complementary to the internally extending flange portion of the body member and with the flange portion for reception within the grooved portion of the cartridge to provide for the cartridge being locked within the opening in the body portion; the internally extending flange portion of the body member and the grooved portion of the cartridge forming a seal to prevent any passage of air from the outside to the inside of the mask, except through the filter cartridge.

<CIT> discloses a known respirator device.

The present disclosure provides a respirator device as set out in claim <NUM>. The respirator device includes a body having a receiver, the receiver including an elastomeric sleeve and a rigid outer portion, and a rigid nozzle element having an outer surface. The elastomeric sleeve and rigid outer portion define a channel, and the rigid nozzle element is configured to be able to slide into the channel. The elastomeric sleeve is configured to deform around the outer surface of the nozzle element when the nozzle element is inserted into the channel, wherein each of the outer surface of the nozzle element and the rigid outer portion of the receiver defines a non-circular shape that prevents rotation between the nozzle element and the rigid outer portion when the nozzle element is inserted into the channel. The body is either a mask body or a housing of a powered air respirator device.

The above summary is not intended to describe each disclosed embodiment or every implementation. The Figures and the Detailed Description, which follow, more particularly exemplify illustrative embodiment.

The disclosure may be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein:.

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

The present disclosure provides a respirator device that includes a body including a receiver and a rigid nozzle element. The receiver includes an elastomeric sleeve and a rigid outer portion defining a channel. When the nozzle element is inserted into the channel of the elastomeric sleeve, the elastomeric sleeve deforms around an outer surface of the nozzle element to form a seal around the nozzle. A filter cartridge, for example, may thus be easily coupled to the body while providing a robust seal that prevents ingress of unwanted contaminants and debris.

<FIG> is a perspective view of an exemplary respirator device <NUM> including a disengaged filter cartridge <NUM>. Exemplary respirator device <NUM> may be a half mask respirator that may be worn by a user to cover the nose and mouth and define an interior air space. Respirator device <NUM> includes a body <NUM>, such as a mask body as shown in <FIG>, and one or more filter cartridges <NUM> located on opposed sides of body <NUM>. Body <NUM> includes one or more receivers <NUM>, for example on opposed sides of body <NUM>, configured to receive a portion of filter cartridge <NUM>. Body <NUM> and filter cartridges <NUM> may be fluidically coupled such that receivers <NUM> cooperate with filter cartridges <NUM> to form an airflow channel between filter cartridges <NUM> and body <NUM>. In other exemplary embodiments, body <NUM> may be a housing of a powered air respirator device, such as a powered air purifying respirator, or a head mounted respirator device.

Body <NUM> can include one or more rigid portions <NUM> and an elastomeric face contacting portion <NUM>. An exhalation valve <NUM> may be positioned on body <NUM> to allow exhaled air to be purged from an interior air space. Respirator device <NUM> may also include a harness assembly (not shown) that is able to support body <NUM> on a user's head.

Filter cartridge <NUM> may be secured to body <NUM> and/or receiver <NUM> by one or more latches, threads, connectors, or other suitable complementary features known in the art. In an exemplary embodiment, respirator device <NUM> includes a cantilever latch <NUM> that secures filter cartridge <NUM> and/or nozzle element <NUM> to receiver <NUM>. In the embodiment of <FIG>, cantilever latch <NUM> is integral to filter cartridge <NUM> and is substantially parallel or co-extending with a nozzle element <NUM>. Receiver <NUM> or body <NUM> include an opening <NUM> and/or mating surface <NUM> that cooperates with cantilever latch <NUM> to provide a secure mechanical connection between body <NUM> and filter cartridge <NUM>.

Cantilever latch <NUM> includes one or more features to facilitate engagement with body <NUM>. In an exemplary embodiment, cantilever latch <NUM> includes an anchoring protrusion <NUM> and a push button <NUM> located along a length, or in some embodiments a distal end, of cantilever latch <NUM>. Anchoring protrusion <NUM> may be configured to cooperate with mating surface <NUM> to assist in securing filter cartridge <NUM> to body <NUM>. Push button <NUM> is configured to detach filter cartridge <NUM> from body <NUM>. A user can apply force or pressure to push button <NUM> to deflect cantilever latch <NUM> and detach anchoring protrusion <NUM> from mating surface <NUM>. Filter cartridge <NUM> may then be disengaged or removed from receiver <NUM>.

<FIG> shows an exemplary filter cartridge <NUM>. Filter cartridge <NUM> filters ambient air, for example, before it passes into an interior air space between body <NUM> and the face of a user. In an exemplary embodiment, filter cartridge <NUM> includes a body portion <NUM> having first and second major surfaces <NUM>, <NUM> and a sidewall <NUM> extending at least partially between first and second major surfaces <NUM>, <NUM>. One or more of first and second major surfaces <NUM>, <NUM>, and/or sidewall <NUM> are fluid permeable to allow air to enter filter cartridge <NUM>. In some exemplary embodiments, filter cartridge <NUM> may comprise primarily filter media without an outer housing or surrounded partially by a housing.

Nozzle element <NUM> extends from a body portion <NUM> of filter cartridge <NUM>. In an exemplary embodiment, nozzle element <NUM> is integral to body portion <NUM> and extends from sidewall <NUM>. In some exemplary embodiments, nozzle element <NUM> is a separate component that may be releasably or permanently joined to body portion <NUM>. In various exemplary embodiments, nozzle element <NUM> may extend from first or second major surfaces <NUM>, <NUM>.

In an exemplary embodiment, nozzle element <NUM> includes a leading end <NUM>, a base end <NUM>, an outer surface <NUM> and an inner surface <NUM> opposite outer surface <NUM>. Inner surface <NUM> defines an airflow channel <NUM>. At any particular location between base end <NUM> and leading end <NUM>, outer surface <NUM> has a cross-sectional area (A) bounded by a perimeter (P). In some exemplary embodiments, the shape of nozzle element <NUM> does not vary between base end <NUM> and leading end <NUM> such that perimeter (P) and cross-sectional area (A) are substantially uniform over a length of nozzle element <NUM>. Alternatively, the shape of nozzle element <NUM> may vary such that, for example, leading end <NUM> exhibits a smaller perimeter (P) and/or cross-sectional area (A) as compared to a location nearer base end <NUM>. A nozzle element <NUM> having a slightly smaller leading end <NUM> may facilitate insertion of nozzle element into receiver <NUM>, as described herein.

<FIG> and <FIG> show an exemplary receiver <NUM> including a rigid outer portion <NUM> and an elastomeric sleeve <NUM>. Receiver <NUM> is configured to engage with filter cartridge <NUM> such that nozzle element <NUM> is able to slide into a channel <NUM> defined by rigid outer portion <NUM> and elastomeric sleeve <NUM>. In an exemplary embodiment, rigid outer portion <NUM> may provide primary structural support and stability between body <NUM> and filter cartridge <NUM> and elastomeric sleeve <NUM> provides a seal around nozzle element <NUM> to prevent ingress of unwanted contaminants or debris from an external environment.

Elastomeric sleeve <NUM> includes a first end portion <NUM>, a second end portion <NUM>, an outer surface <NUM> and an inner surface <NUM> in part defining channel <NUM>, and a longitudinal length (l) (<FIG>) in the direction of channel <NUM> between first end portion <NUM> and second end portion <NUM>. At any particular location along length (l), inner surface <NUM> defines a cross-sectional area (a) of channel <NUM> and outer surface <NUM> defines an outer perimeter (p). In some exemplary embodiments, the shape of elastomeric sleeve <NUM> does not vary over length (l) such that perimeter (p) and/or cross-sectional area (a) are substantially uniform at any particular location. Alternatively, the shape of elastomeric sleeve <NUM> may vary over length (l) such that, for example, first end portion exhibits a smaller perimeter (p) and/or cross-sectional area (a) as compared to a location nearer second end portion <NUM>. In an exemplary embodiment, nozzle element <NUM> is relatively larger than elastomeric sleeve <NUM> such that an interference occurs when nozzle element <NUM> is inserted into elastomeric sleeve <NUM>. An elastomeric sleeve <NUM> having a slightly smaller leading end <NUM>, for example, may facilitate sealing between inner surface <NUM> and nozzle element <NUM>, as described further herein.

Elastomeric sleeve <NUM> includes at least a portion that is floating or otherwise not in direct contact with a rigid component that constrains outward elastic deformation or expansion. For example, at least a portion of outer surface <NUM> is not in direct contact with a rigid component that constrains outward elastic deformation or expansion. In an exemplary embodiment, first end portion <NUM> is a floating end and is not engaged with a rigid component of body <NUM>. Elastomeric sleeve <NUM> further includes an intermediate portion <NUM> that is not backed by a rigid component that could constrain outward elastic deformation or expansion. An elastomeric sleeve including at least a portion not backed by a rigid component allows elastomeric sleeve to flex and/or articulate. Elastomeric sleeve <NUM> may thus track or follow movement of nozzle element <NUM> such that a robust seal may be maintained despite possible relative motion between body <NUM> and filter cartridge <NUM>.

In an exemplary embodiment, elastomeric sleeve <NUM> includes sections of varying wall thickness and/or having a contoured shape such that elastomeric sleeve <NUM> includes one or more of a rib <NUM>. Rib <NUM> may be located at a position of inner surface <NUM> configured to contact outer surface <NUM> of nozzle element <NUM>. Rib <NUM> may facilitate continuous contact with outer surface <NUM> to provide a desired seal. In an exemplary embodiment, the greatest interference between nozzle element <NUM> and elastomeric sleeve <NUM> may be concentrated at the location of rib <NUM>. Providing a limited area of interference may reduce the force a user must exert to engage filter cartridge <NUM> with body <NUM> while ensuring a consistent seal.

<FIG> shows exemplary nozzle element <NUM> engaged with receiver <NUM> such that nozzle element <NUM> is positioned in a channel defined by receiver <NUM>. Elastomeric sleeve <NUM> is able to conform to outer surface <NUM> of nozzle element <NUM> when filter cartridge <NUM> is inserted into receiver <NUM>. In an exemplary embodiment, insertion of a relatively larger nozzle element <NUM> into a relatively smaller elastomeric sleeve <NUM> causes elastomeric sleeve <NUM> to deform, such as by expanding for example, around outer surface <NUM> of nozzle element <NUM>. In an exemplary embodiment, elastomeric sleeve expands such that perimeter (p) of outer surface <NUM> (<FIG>) and/or cross-sectional area (a) defined by inner surface <NUM> are larger when nozzle element <NUM> is positioned in elastomeric sleeve <NUM> as compared to when nozzle element <NUM> is not positioned in elastomeric sleeve <NUM>.

Elastic deformation or expansion of elastomeric sleeve <NUM> around nozzle element <NUM> results in a restoring force acting to restore elastomeric sleeve to its neutral state. Such a force causes elastomeric sleeve <NUM> to clamp around outer surface <NUM> of nozzle element <NUM> and promote continuous contact between elastomeric sleeve <NUM> and outer surface <NUM>.

In an exemplary embodiment, elastic deformation or expansion of elastomeric sleeve <NUM> in a configuration in which at least a portion of elastomeric sleeve <NUM> is out of contact with a rigid component of body <NUM> results in a tension around elastomeric sleeve <NUM>, as opposed to compression that may occur if elastomeric sleeve were compressed between nozzle element <NUM> and a rigid component of body <NUM>, for example. In an exemplary embodiment, elastomeric sleeve <NUM> exhibits a hoop tension when nozzle element <NUM> is engaged with receiver <NUM>. In some exemplary embodiments, elastomeric sleeve <NUM> can be described as having a portion in tension in a direction (z) perpendicular to both an airflow axis (x) and radial thickness (y) of elastomeric sleeve <NUM>.

Elastomeric sleeve <NUM> is sealingly engaged, directly or indirectly, with a feature of receiver <NUM> when filter cartridge <NUM> is engaged with body <NUM>. In an exemplary embodiment, elastomeric sleeve includes a sealing surface <NUM> that contacts an internal surface or flange <NUM> of receiver <NUM>. Alternatively or in addition, one or more connectors <NUM> may sealingly join receiver <NUM> and elastomeric sleeve. In an exemplary embodiment, sealing surface <NUM> and connector <NUM> are positioned adjacent flange <NUM> such that sealing engagement is promoted by insertion of nozzle element <NUM> into channel <NUM>. In an exemplary embodiment, elastomeric sleeve <NUM> and/or connector <NUM> are permanently joined to body <NUM>. In other exemplary embodiments, elastomeric sleeve <NUM> and/or connector <NUM> may be removed and replaced.

Elastomeric sleeve <NUM> may be made of any suitable material that may repeatedly elastically deform around a filter cartridge. In an exemplary embodiment, elastomeric sleeve <NUM> is made from a thermoset silicone material such as ELASTOSII, <NUM> / 60A available from Wacker Chemical Corp. of Adrian, MI. Other suitable materials include thermoplastic vulcanates (TPV), thermoplastic elastomers (TPE), moldable rubbers, urethanes, moldable elastomers, combinations thereof, and other suitable materials as known in the art.

Elastomeric sleeve has a length sufficient to allow a consistent seal around nozzle element <NUM> while allowing for adequate dimensional tolerance and relative motion between filter cartridge <NUM> and body <NUM>. In an exemplary embodiment, elastomeric sleeve <NUM> has a length (l) in a longitudinal direction of channel <NUM> that is significantly greater than a wall thickness (t) of elastomeric sleeve <NUM>. In various exemplary embodiments, elastomeric sleeve <NUM> has a length (l) between <NUM> and <NUM>, <NUM> and <NUM>, or of about <NUM>, and wall thickness (t) is between <NUM> and <NUM>, <NUM> and <NUM>, or of about <NUM>. In some exemplary embodiments, wall thickness (t) is substantially uniform over length (l) and in other exemplary embodiments wall thickness (t) varies over length (l).

The shape, positioning, and configuration of nozzle element <NUM> and receiver <NUM> may be selected to allow filter cartridge <NUM> to reside close to the face or head of a wearer and to exhibit little or no motion relative to body <NUM>. The outer surface <NUM> of nozzle element <NUM> and rigid outer portion of receiver <NUM> exhibit a non-circular shape that prevents rotation between the components. In various embodiments, nozzle element <NUM> exhibits an elongated oval shape, elliptical shape, irregular shape, or other suitable non-circular shape that prevents rotation between the nozzle element and the rigid outer portion. An elongated oval shape, for example prevents rotation and facilitates expansion of elastomeric sleeve <NUM> around nozzle element <NUM> such that a continuous seal is provided. Nozzle element <NUM> extends a sufficient distance into receiver <NUM>. Complementary shapes of nozzle element <NUM> and receiver <NUM> provide a stable connection and prevent inadvertent disengagement. Sufficient engagement between nozzle element <NUM> and receiver <NUM> minimizes relative motion and provides a perception of a robust connection between filter cartridge <NUM> and body <NUM>.

Filter cartridge <NUM> and receiver <NUM> may provide additional features to minimize relative movement between filter cartridge <NUM> and receiver <NUM> when engaged. Filter cartridge <NUM> and receiver <NUM> may include one or more alignment features, such as protrusions, channels, or other suitable alignment features as known in the art that cooperate to align nozzle element <NUM> and receiver <NUM>. In an exemplary embodiment, a first alignment feature <NUM> in the form of a protrusion and a second alignment feature <NUM> in the form of a channel, slot, or groove, for example, cooperate during engagement of nozzle element <NUM> and receiver <NUM>. First and second alignment features <NUM>, <NUM> may assist in aligning nozzle element <NUM> and receiver <NUM> during insertion, and securing the components to prevent relative motion when engaged.

Nozzle element <NUM> may include one or more ribs <NUM> extending outwardly from outer surface <NUM>. In an exemplary embodiment, ribs <NUM> may be dimensioned to cooperate with rigid outer portion <NUM> of receiver <NUM> to provide a close fit between nozzle element and receiver <NUM>. Ribs <NUM> may facilitate secure mechanical engagement between nozzle element <NUM> and receiver <NUM> without an interference fit over an extended area and thus may limit force exerted by a user when engaging nozzle element <NUM> to body <NUM>.

<FIG> shows a partial cross-sectional view of another exemplary respiratory device <NUM>. Exemplary respiratory device <NUM> includes features similar to the features of respirator device <NUM> described above, and having an elastomeric sleeve <NUM> including a first end <NUM> that engages a component of body <NUM>.

In an exemplary embodiment, elastomeric sleeve <NUM> includes a first end portion <NUM>, a second end portion <NUM>, an outer surface <NUM> and an inner surface <NUM> in part defining channel <NUM>. A first end portion <NUM> engages a component of body <NUM>. In an exemplary embodiment, outer surface <NUM> contacts, directly or indirectly, one or more interior walls, for example, that divide a first chamber <NUM> from a second chamber <NUM> within the interior space defined by body <NUM>.

Elastomeric sleeve <NUM> includes at least a portion that is floating or otherwise not in direct contact with a rigid component that constrains outward elastic deformation or expansion. In an exemplary embodiment, elastomeric sleeve <NUM> includes an intermediate portion <NUM> that is not backed by a rigid component that could constrain outward elastic deformation or expansion. A space <NUM> is present adjacent outer surface <NUM> proximate intermediate portion <NUM>. An elastomeric sleeve <NUM> including at least a portion not backed by a rigid component allows elastomeric sleeve to flex and/or articulate. Elastomeric sleeve <NUM> may thus track or follow movement of nozzle element <NUM> such that a robust seal may be maintained despite possible relative motion between body <NUM> and filter cartridge <NUM>.

Elastomeric sleeve <NUM> is able to conform to outer surface <NUM> of nozzle element <NUM> when filter cartridge <NUM> is inserted into receiver <NUM>. In an exemplary embodiment, insertion of a relatively larger nozzle element <NUM> into a relatively smaller elastomeric sleeve <NUM> causes elastomeric sleeve <NUM> to elastically deform or expand around outer surface <NUM> of nozzle element <NUM>. In an exemplary embodiment, elastomeric sleeve expands such that a perimeter (p) of outer surface <NUM> at intermediate portion <NUM> and/or cross-sectional area (a) defined by inner surface <NUM> are larger when nozzle element <NUM> is positioned in elastomeric sleeve <NUM> as compared to when nozzle element <NUM> is not positioned in elastomeric sleeve <NUM>.

In an exemplary embodiment, expansion of elastomeric sleeve <NUM> with at least a portion of elastomeric sleeve <NUM> out of contact with a rigid component of body <NUM> results in a tension around elastomeric sleeve <NUM>, as opposed to compression that may occur if elastomeric sleeve were compressed between nozzle element <NUM> and a rigid component of body <NUM>, for example. In an exemplary embodiment, elastomeric sleeve <NUM> exhibits a hoop tension when nozzle element <NUM> is engaged with receiver <NUM>. In some exemplary embodiments, elastomeric sleeve <NUM> can be described as having a portion in tension in a direction (z) perpendicular to both an airflow axis (x) and radial thickness (y) of elastomeric sleeve <NUM>.

A respirator device having an elastomeric sleeve as disclosed herein provides several features and advantages. An elastomeric sleeve including at least a portion that is floating or otherwise not in direct contact with a rigid component that constrains outward expansion provides significant advantages in creating a seal between a nozzle element and body of a respiratory protection device. Elastomeric sleeve may flex and articulate and thus maintain sealing contact with a nozzle element even if the nozzle element moves or articulates relative to the receiver. Further, an elastomeric sleeve as disclosed herein provides an adequate seal while minimizing insertion force required by a user. A filter cartridge may be easily inserted into a receiver to create a secure connection without rotation. The force exerted by a user during insertion to cause elastomeric sleeve to expand around a nozzle element may be minimal as compared to a force required if a seal were formed by compressing a sealing element against a rigid backing component, for example.

Claim 1:
A respirator device (<NUM>, <NUM>), comprising:
a body (<NUM>, <NUM>) comprising a receiver (<NUM>, <NUM>) having an elastomeric sleeve (<NUM>, <NUM>) and a rigid outer portion (<NUM>), said elastomeric sleeve and rigid outer portion defining a channel (<NUM>, <NUM>); and
a rigid nozzle element (<NUM>, <NUM>) having an outer surface (<NUM>, <NUM>) and configured to be able to slide into the channel;
wherein the elastomeric sleeve is configured to elastically deform or expand around the outer surface of the rigid nozzle element when the rigid nozzle element is inserted into the channel so as to provide a restoring force acting to restore elastomeric sleeve to its neutral state, wherein the elastomeric sleeve includes at least a portion that is not in contact with a rigid component of the body, wherein expansion of the elastomeric sleeve with said at least a portion of the elastomeric sleeve out of contact with a rigid component of body results in a tension around the elastomeric sleeve, as opposed to compression that may occur if the elastomeric sleeve were compressed between the rigid nozzle element and a rigid component of body;
and wherein each of the outer surface of the rigid nozzle element and the rigid outer portion of the receiver defines a non-circular shape that prevents rotation between the rigid nozzle element and the rigid outer portion when the rigid nozzle element is inserted into the channel; and
wherein the body is either a mask body or a housing of a powered air respirator device.