Patent Description:
In the 21st century, increasingly people are becoming more active, health conscious and taking up various sports and recreational activities, such as running, cycling, triathlon, gym workouts, etc. There are many types of sporting or recreational equipment that are available to meet these sports training needs. One of the relatively new additions to these types of recreational equipment is a type of inspiratory muscle training respiration masks. Essentially, the masks add inspiratory resistance by restricting the airflow to the masks while doing exercise, and the wearers need to overcome this added resistance to breathe in air enough to provide the oxygen needed for the body to function. Depending on the level of difficulties, the wearer is required to breathe harder than he or she normally does, thus loading the inspiratory muscles associated with breathing. Research has found that this type of training mask is effective to boost lung capacity, strengthen breathing muscles and improve overall fitness.

There are a number of issues / potential improvements with the currently available sports training masks:.

The most commonly used personal respiratory protection mask type today is paper mask, and "N95" is one of the popular standards to define a class of such a mask type. Most paper masks are simple and light, however, their protection efficiency can be easily compromised by air gaps between the mask and the face.

<CIT> disclosed a "N95" type mask. This patent disclosed a molded, cup-shaped face mask for medical and dental personnel. The mask had a first, second and third layer. Edge portions of the layers were substantially free of adhesion to one another, and outer edges of the mask were free of any peripheral seal or the like, so that the edge portions of all three layers were movable relative to each other and present a soft, comfortable feel to the wearer. Exhalation of air through the mask was facilitated by the flexible nature of the edge portions, and during inhalation the flexible edge portions were drawn toward a position of conformed contact with the wearer's face.

An air purifying respirator, or APR, is an upgrade to N95 type of passive masks with improved facial seal and filter efficiency and dust capacity. However, it is still a passive mask, and like N95 masks, one has to make extra effort to breathe through the filter media; a fair part of the used air gets rebreathed, increasing the CO<NUM>, moisture and temperature in the mask; all these resulting in discomfort over long period of use.

<CIT> disclosed a wearable training mask providing varied inhalation resistance settings. The mask includes a depth defining and air impermeable body having an exterior surface and an interior surface exhibiting a perimeter extending seal such that the body is adapted to overlay a wearer's mouth and nose. A plurality of air admittance valve subassemblies are provided and incorporated into locations along the body. Each of the valve subassemblies exhibit multiple resistance settings for affecting a degree of air flow into the mask in response to inhalation by the wearer. Straps extending from said body have inter-engaging ends affixing about the wearer's head. This mask cannot automatic adjust the air flow to suit different user in different environment or altitude. This mask lacks the mechanically ability to assist the air ventilation of the user within the mask. Further this mark does not provide any air filters to block or limit pollutants entering the airways of the user.

A powered air purifying respirator, or PAPR, are generally used in heavily polluted or hazardous industrial environment. A typical PAPR uses power to draw ambient air from the atmosphere through a filter element, to pressurize it, and transfer it to the airways of the user via a conduit and mask. A PAPR ensures that the supply of air remains filtered or purified under all circumstances by maintaining a positive pressure inside the mask. As a result, the protection efficiency can be maintained high, and the CO2 and moisture in the mask can be kept low, thus a PAPR can provide a much better protection and breathing comfort than a paper mask, especially for a prolonged use.

<CIT> disclosed a breathing apparatus, comprising: a filter arranged to provided filtered air entering the breathing apparatus to a user; an air flow generator arranged to receive and pressurize the filtered air; a bypass valve arranged to allow the filtered air to allow the filtered air to pass therethrough; a mask for providing the filtered air to an airway of the user; and a manifold having a first pathway for allowing filtered air via the air flow generator, a second pathway for allowing filtered air via the bypass valve, the second pathway being arranged to allow the filtered air to avoid air flow generator, and an outlet in fluid communication with the mask, whereby the filtered air is provided to the mask through the air flow generator or the bypass valve.

However, the prior art PAPR systems were specified solely for industrial and professional applications. That is, they have not been designed for use by the general public in everyday situations. Therefore, most PAPR systems are typically big, bulky, heavy and expensive.

In recent years, the demand for a better respiratory protection mask for general public for recreational activities has been strong. In particular, many Chinese cities suffer from severe smog and particulate air pollution across each year, and good quality paper masks are often sold out or not practical for physical activities such as running or exercising.

A number of low performance powered or "hybrid" masks have become available. Most of these hybrid masks have the blower, battery, control electronics and filter media all fitted in the mask body. In a sense, they have the form factor of a typical paper mask, and they produce some motorised air to the mask, which helps to flush out the used air thus improving some comfort. However, the main shortcoming of these hybrid masks is that the air flow is normally not sufficient to meet the breathing demand for high exertion activities, such as in outdoor running and cycling sports. Further, most of these hybrid masks do not meet the recognised relevant international standard for a PAPR due to the low flow capability. Therefore, these hybrid masks cannot be used in demanding and serious applications.

<CIT> teaches a respirator or breathing apparatus assembly, including a mask component and a neck component. The mask component is adapted to substantially surround the mouth and/omostrils of the user, whilst the neck component is attachable thereto and is adapted to surround the back of the neck of the user. The neck component includes the flow generator and associated processing means to receive unfiltered air from the surrounding environment, filter the unfiltered air and provide the filtered air to the mask.

<CIT> teaches a respirator hood assembly that has a bag, a half mask and an air filtration unit that defines a rigid external structure around at least a portion of the bag that supports the hood and allows the user to quickly don the hood.

<CIT> teaches a breathing apparatus including a face mask adapted to substantially cover a face of a user and a neck component attached to the face mask and surrounding the user's neck. The face mask has a peripheral region which forms a pneumatic seal against the face and an air inlet arranged proximal to the peripheral region. The neck component houses a flow generator configured to receive unfiltered air from outside of the breathing apparatus, filter the unfiltered air, and convey the filtered air to the face mask through the air inlet.

<CIT> teaches a respiration apparatus, including an air flow generator, a filter, and a delivery airway, the air flow generator being arranged to generate positive pressure air flow, the filter being arranged to filter air prior to inhalation by a user, and the delivery airway being arranged to transport the positively pressurised air and to connect to a mask to deliver the pressurised and filtered air to the mask for respiration by a user of the respiration apparatus.

<CIT> teaches a kind of resistance breathing equipment includes mask, which has periphery and extend through aperture therein, and suitable for the mouth and nose of covering user so that the face of periphery and user form gas-tight seal. Insert, which is arranged in the aperture of mask and has, extends through entrance aperture therein. Adjusting slider is positioned adjacent to insert, with extending through its entrance aperture, and it can move between the first position and the second position, in first position, the Part I of entrance aperture is overlapping with the entrance aperture of insert, in the second place, the larger Part II of entrance aperture is overlapping with the entrance aperture of insert. Regulating wheel is attached to insert and can be rotatably moved between the first and second positions, so that adjusting slider moves between its first and second position.

Other objectives and advantages will become apparent when taken into consideration with the following specification and drawings.

It is also an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

The present invention relates to a multi-purpose modular respirator as claimed in claim <NUM>. Additional features are defined by the dependent claims.

Thus, in one aspect of the invention, there is provided a multi-purpose modular respirator (<NUM>) comprising:.

Preferably, the modular respirator further comprisies a neck band joining the blower unit and the controlling unit.

Preferably, the power unit is adapted to supply power to the electric blower via an electric cable passing through the neck band.

Preferably, the controller is in communication with the electric blower through an electric cable passing through the neck band.

Preferably, the controller is in communication with the electric blower through wireless communication.

Preferably, the neck band is selectively adjustable by the user.

Preferably, the neck band comprises an inner sleeve joining one of the blower unit and controlling unit, an outer sleeve joining the other of the blower unit and controlling unit, such that the inner sleeve is movable within the outer sleeve.

Preferably, the neck band comprising a latch for fastening the inner sleeve with the outer sleeve on a fix position.

Preferably, the electric cable is a coiled cable.

Preferably, the inner sleeve has a lumen adapted to allow the electric cable to pass therethrough.

Preferably, the blower unit comprises a blower unit enclosure adapted to hold an electric blower, and a pre-filter.

Preferably, the electric blower comprises a blower enclosure housing an electric motor attached to an impeller.

Preferably, the electric motor is a brushless direct current electric motor.

Preferably, the electric motor comprises a stator with a plurality of protruding ribs.

Preferably, electric motor comprises a plurality of body vane for supporting the electric motor inside the electric blower and directing a fluid to pass therethrough.

Preferably, the impeller comprises a substantially conical stem, and a plurality of impeller vanes extending radially from the stem.

Preferably, the impeller can produce reverse air flow when rotates in reverse direction.

Preferably, the blower enclosure comprises a front shell releasably connected to a rear shell, such that the electric motor is adapted to securely fit inside the blower enclosure.

Preferably, the front shell comprises an aperture adapted to allow fluid to pass therethrough.

Preferably, the rear shell comprises an aperture for cables connected to the electric motor to pass through, and at least one aperture for fluid to pass therethrough.

Preferably, the front shell comprises at least one male snap-fit members to releasable engage with a corresponding female snap-fit members of the rear shell.

Preferably, the front shell is releasably secured to the rear shell with screws.

Preferably, the blower unit further comprises a filter cover covering the pre-filter.

Preferably, the pre-filter is adapted to filter particulars with particular size of over <NUM>.

Preferably, the blower unit enclosure comprising a top shell removably engages with a bottom shell, such that the electric blower and the pre-filter are securely fit inside the blower unit.

Preferably, the top shell comprises at least one male snap-fit members to releasable engage with a corresponding female snap-fit members of the bottom shell.

Preferably, the top shell is releasably secured to the bottom shell with screws.

Preferably, the controlling unit comprises one or more user interfaces displaying the status of the modular respirator.

Preferably, one of the user interface comprises a plurality of light emitting diodes.

Preferably, one of the user interface digital display screen.

Preferably, one of the user interface comprises a touch screen.

Preferably, the controlling unit comprises a power switch for switching the modular respirator on or off.

Preferably, the power unit comprises a rechargeable battery.

Preferably, the rechargeable battery is a Lithium ion battery.

Preferably, the filter unit comprises a serviceable case for accessing the fluid filter.

Preferably, the filter outlet comprises a pipe thread joint for fastening a corresponding pipe thread joint on the inlet of the mask assembly.

Preferably, the filter outlet is adapted to receive an elastic spacer inside the pipe thread joint.

Preferably, the fluid filter has a conical shape.

Preferably, the filter unit comprises one of the male push-fit connector or female push-fit connector for connecting a complementary push-fit connector.

Preferably, the male push-fit connector comprises stud having a locking groove for receiving a locking latch.

Preferably, the female push-fit connector comprises a socket adapted to releasable engage with the stud, wherein the socket has one or more spring-loaded latch for latching upon the locking groove of the stud.

Preferably, the female push-fit connector comprising a spring-loaded ring for releasing the spring-loaded latch from the locking groove.

Preferably, the male and female push-fit connector comprises a pipe thread connector to engage with a complementary pipe thread connector.

Preferably, the exhaust unit comprises a pipe thread connector at the exhaust inlet for connecting to a complimentary pipe thread connector at the mask outlet.

Preferably, the exhaust unit comprises a mounting plate for supporting the one-way valves.

Preferably, the exhaust unit comprises a filter compartment for housing an exhalation filter.

Preferably, the filter compartment is located at the exhaust outlet.

Preferably, the filter compartment has a mesh opening.

Preferably, the mesh opening comprises a resistance dial for controlling air flow exit from the exhaust unit.

Preferably, the exhaust unit has one of the male and female push-fit connector adapted to engage a complimentary push-fit connector.

Preferably, the exhaust unit has a pressure port to interface with a pressure sensor.

Preferably, the modular respirator further comprises a neck band assembly having first stub attached to one end of a neck band, and a second stub attached to another end of the neck band, wherein the first stub and the second stub are adapted to engage with a push-fit connector.

Preferably, the first stub comprises an adjustment means for adjusting the inhalation resistance of the fluid.

Preferably, second stub comprises a pressure sensor for sensing the pressure of the fluid inside the mask.

Preferably, the neck band assembly comprises a adjusting means for adjusting the length of the neck band.

Preferably, the neck band comprises a sleeve adapted to allow a coil cable to fit therethrough.

Preferably, the sleeve is made of elastic materials.

Preferably, the modular respirator further comprises one or more head band.

Preferably, the mask assembly comprises one or more hooks located towards the top, bottom, or centre of mask assembly, wherein the hooks are adapted to engage with pull-over bands for securing the mask assembly on the user.

Preferably, the modular respirator further comprising one or more sensing devices, wherein the sensing device has a self-sustained controller and power supply.

Preferably, the sensing devices is adapted to measure CO<NUM> concentration level.

Preferably, the blower unit is adapted to be placed at a person's back of the person's neck having an air pipe, an electric blower for driving fluids from a blower inlet to a blower outlet.

Preferably, the air pipe is connected between the filter unit and the controlling unit, and is made of rubber having a section of bellows at each side of the tube.

Preferably, the air pipe is adapted to be a fastening mechanism for the respirator.

Preferably, the modular respirator further comprises a coiled electrical cable for conducting electricity to the blower unit.

Preferably, the controlling unit has a thread connector at an inlet end and a push-fit connector at an outlet end; the mask assembly has a quick connect interface at each end of the mask.

Preferably, the air pipe comprises a thread connector assembly adapted to adjust a length of the air pipe and to releasably fasten to the controlling unit and the filter unit.

Features and advantages of the present invention will become apparent from the following description of embodiments thereof, by way of example only, with reference to the accompanying drawings, in which:.

Referring to <FIG>, in one embodiment of the present invention, there is provided a modular respirator <NUM> comprising an elongate filter unit <NUM> having a filter inlet <NUM>, a filter outlet <NUM>, and a replaceable fluid filter <NUM> for filtering pollutant in the fluid, such as air. The modular respirator <NUM> comprises an elongate exhaust unit <NUM> having an exhaust inlet <NUM>, an exhaust outlet <NUM>, and one or more one-way valves <NUM>.

The modular respirator <NUM> further comprises a mask assembly <NUM> having a mask for covering the oral and nasal passage of a user, a mask inlet <NUM> at one end of the mask, a mask outlet <NUM> at an opposite end of the mask, wherein the mask inlet is releasably fastened to the filter outlet <NUM>, and the mask outlet is releasably fastened to the exhaust inlet <NUM>.

The filter unit <NUM> is located around an anterior triangle on one side of a neck and the exhaust unit <NUM> is located around or in the vicinity of an anterior triangle on an opposite side of the neck forming a tightly sealed passage for fluid to pass through the filter unit, the mask <NUM> and the exhaust unit.

As the shape of the filter unit <NUM> and the exhaust unit <NUM> are elongate shapes, both are adapted to wrap around at least partially around the neck in the vicinity of the anterior triangles. This is different to other dish shaped filter which are not adapted to wrap around the neck. The filter unit <NUM> and the exhaust unit <NUM> are similar in shape, size, and weight so that they are balance around both sides of the neck.

In one embodiment, the pipe thread connectors complies with ISO <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>, or the national pipe thread standards.

The modular respirator <NUM> further comprising a blower unit <NUM> having a blower inlet <NUM>, a blower outlet <NUM> and an electric blower for driving fluid from the blower inlet to the blower outlet; and a controlling unit <NUM> having a power unit <NUM> and a controller <NUM> for controlling the electric blower. The blower outlet <NUM> is releasably connected with the filter inlet <NUM> of the filter unit <NUM>, and the controlling unit <NUM> is releasably connected to the exhaust unit <NUM>.

Preferably, the blower unit <NUM> and the controlling unit <NUM> have elongate shapes. As the shape of the blower unit <NUM> and the controlling unit <NUM> are elongate shapes, both are adapted to wrap around at least partially around the neck in the vicinity of the stemomastoid muscles and the posterior triangles. The blower unit <NUM> and the controlling unit <NUM> are both similar in shape, size, and weight so that they are balance around both sides of the neck. The blower unit <NUM> and the controlling unit <NUM> connect to a neck band <NUM> around the back of the neck. In one embodiment, the blower unit <NUM> and the controlling unit <NUM> may rest their weight upon the shoulders of the user.

In one embodiment of the present invention, there is provide a modular respirator <NUM> for sport comprising a mask assembly <NUM> adapted to cover the nasal and oral passage of a user, a filter unit <NUM>, an exhalation unit <NUM>. In another embodiment, the modular respirator <NUM> further comprises an air flow generator <NUM> including a blower unit <NUM>, a power unit <NUM>, and a PCB (or controller) unit <NUM>. The modules of the respiratory <NUM> is preferably connect with one or more connection assembly <NUM>. Optionally, additional elastic neck bands and / or head bands (not shown) may be provide for further distribution of load.

The filter unit <NUM> and the exhalation unit <NUM> are connected with the mask <NUM> via the pipe thread connector, designed to make connect and disconnect easy. And it also makes the connection reliable and leak free.

In one embodiment where an air flow generator <NUM> is used, the filter unit <NUM> and the exhalation unit <NUM> are connected to the blower unit <NUM> and controlling unit <NUM> via one or more connection assembly <NUM> or push-fit connectors. The connection assembly <NUM> provides a locking mechanism, wherein the connector assembly can be engaged with other module by simply pushing the parts together, and released by manipulating a ring <NUM> on the connection assembly.

In another embodiment where no air flow generator <NUM> is installed, the filter unit <NUM> and the exhalation unit <NUM> are connected to a neck band assembly <NUM>.

The embodiment without an air flow generator <NUM> can be easily convert to one with an air flow generator. This is achieved by simply removing the neck band assembly <NUM> that is connected to the connection assembly <NUM> and connecting the air flow generator <NUM>.

Similarly, to change from a respiratory <NUM> with air flow generator <NUM> to one without an air flow generator, the user simply needs to remove the air flow generator <NUM> via the connection assembly <NUM>, and replace it with a neck band assembly <NUM>.

This modular structure allows one design to be configured to two separate products, which allows an easy upgrade from the non-powered respiratory to a powered respirator, or vice versa, from the powered respiratory to the non-powered respiratory for meeting some specific needs.

Referring to <FIG>, the mask assembly <NUM> consists a mask <NUM> with frame and a cushion that is in contact with the face to form an air tight seal covering nasal and oral passage of a person, and two pipe thread connectors <NUM> at the mask inlet <NUM> and mask outlet <NUM>. The preferred material for the cushion is silicone rubber. Other rubber or TPE material can be used as well. The preferred frame material is Polycarbonate, and preferably it is transparent, or with colour pattern, but need to be able to see the mouth movement while talking.

<FIG> shows a front view of a mask <NUM> in one preferred embodiment of the present invention. In another embodiment as shown in <FIG> and <FIG>, a drain valve is added at the bottom of the mask <NUM> to allow accumulated condensation or sweat to drain away. The position of the valve makes minimum impact on the general appearance of the mask.

<FIG> shows an embodiment of the tread connector <NUM> at the mask inlet <NUM>. In another embodiment, an inhalation one-way valve is fitted to the end of the thread connector <NUM> to stop breathed air going back to the filter unit <NUM>.

Preferably, the said mask assembly <NUM> is moulded or press-fit with the frame in polycarbonate, and the mask assembly is attached to the face by pull-over band / bands <NUM>. The pull-over hands <NUM> can be a head band or neck band. The pull-over band <NUM> may be made of elastic material. In one embodiment, the material of the frame is made of silicone, so that the whole mask is moulded in silicone in one piece. Preferably, the cushion has an air inlet port / mask inlet <NUM> at one side to connect to the said filter unit <NUM>, and an air outlet port / mask outlet <NUM> at the other side to connect to the said exhalation unit <NUM>; both the filter unit <NUM> and the exhalation unit <NUM> are preferably connected to the corresponding port with a corresponding thread connector <NUM>. In one embodiment, the cushion is made of silicone. The thread connector <NUM> of the mask inlet <NUM> is adapted to engage with a complementary thread connector of the filter outlet <NUM> of the filter unit <NUM>. The thread connector <NUM> of the mask outlet <NUM> is adapted to engage with a complementary thread connector of the exhaust inlet <NUM> of the exhaust unit <NUM>.

Preferably, the frame has one pair of hooks located towards the top of the said frame with one at each side of the frame, and another pair of hooks located towards the bottom of the frame with one at each side of the frame. The pull-over bands <NUM> tie to the said two pair of hooks and are preferably used in one of the two ways: A - one band is used for tightening at the upper back of the head, and the other band is used for tightening at the lower back of the head; B - one band is used for tightening at one of the ears, and the other band is used for tightening at the other ear.

In another embodiment, the two separately located said pair of hooks can be replaced with one pair of centre-hooks, where the said centre-hooks are located at around the centre line of the said frame with one at each side of the said frame.

Preferably, the said pull-over bands <NUM> tie to the said pair of centre-hooks and can be used in one of the two ways: A - one band is used for tightening at the upper back of the head, and the other band is used for tightening at the lower back of the head; B - one band is used for tightening at one of the ears, and the other band is used for tightening at the other ear.

Referring to <FIG>, the filter unit <NUM> connects to the mask assembly <NUM> via a pipe thread <NUM> at its filter outlet <NUM>. An elastic spacer such as an O-ring or washer is fitted at the end of the thread to ensure that the seal is tight. The filter <NUM> unit comprises: a filter case <NUM>, a filter <NUM>, a filter inlet <NUM> and a filter outlet <NUM>.

Preferably, the filter <NUM> is adapted to block the fine particles or pollutants in the air that are harmful to the wearer. The filter <NUM> may optionally have nuisance level harmful gas absorption capability, such as by impregnating activated carbon with the filter media of the filter. The filter case <NUM> of the filter <NUM> is preferably elongate in shape and in cylindrical or conical form and is tapered, and preferably larger at the end of the filter inlet <NUM> to allow a larger air inlet passage in order to reduce the flow resistance. The filter element of the said filter <NUM> is preferably tapered in cone shape in order to increase the air path of the cross section area of the filter at its outlet <NUM> to minimise flow resistance. The filter unit <NUM> has an inlet portion where an elastic spacer is fitted to groove to form an air-tight seal with the connection assembly <NUM> or push-fit connectors.

In one embodiment, the filter unit <NUM> has an inlet portion where an elastic spacer is fitted to form an air-tight seal with one of the male and female push-fit connectors. When the filter unit <NUM> comprises a male push-fit connector, it is adapted to engage with a complimentary push-fit connector that is a female push-fit connector. When the filter unit <NUM> comprises a female push-fit connector, it is adapted to engage with a complimentary push-fit connector that is a male push-fit connector. In one embodiment the inlet portion also has a spring locking groove to work with the connection assembly <NUM>.

The filter unit <NUM> is removable from the respirator <NUM> for replacement. In one embodiment, the filter unit <NUM> comprises a serviceable case adapted to provide access for replacing the fluid filter. The interior of the filter unit <NUM> is accessible for cleaning and replacement of the filter <NUM>. Other type of filter such as flat filter or cylindrical filter can be used instead of the conical shaped filter. In one embodiment, the filter unit <NUM> provides a slot for receiving a removable air filter for easy replacement. In one embodiment, the filter <NUM> is a high-efficiency particulate absorber air filter or ultra-low penetration air filter. Depending on the type of air filter, an air flow generator <NUM> may be required to assist the air flow.

Referring to <FIG>, the Exhalation Unit <NUM> is adapted to connect to the mask assembly <NUM> via the pipe thread <NUM> at the end of the inlet <NUM>. An elastic spacer such as an O-ring or washer is fitted at the end of the thread <NUM> to provide a tight sealing.

The exhalation unit <NUM> is adapted to convey exhaled air from the mask assembly <NUM> to the environment outside the respirator <NUM>. The exhalation unit <NUM> comprises at least one exhalation valve <NUM>, an optional exhaled air filter <NUM> and a cover <NUM> to conceal the exhalation valve <NUM> and the exhaled air filter <NUM>. Typically, the exhalation valve <NUM> is a one way valve such that air may flow from the mask assembly <NUM> to the exhaled pathway but not vice versa.

The exhaust unit <NUM> has a mounting plate for supporting the one-way valves. In one preferred embodiment, there is provided a dial on a filter cover or the mesh cover <NUM> to adjust the air resistance of the exhaust outlet <NUM>. So the modular respirator <NUM> could have both inlet and outlet resistance adjustment options.

The exhalation unit <NUM> may have access to an air pressure sensor sensing an air connection portion and communicating with the controlling unit <NUM>. In one preferred embodiment, pressure sensor is positioned in the controlling unit <NUM>. A small air passage <NUM> is constructed to allow the air pressure sensor to sense the air pressure of the mask <NUM>. An O-ring is fitted on the air connection portion to form an air-tight seal with the connection assembly <NUM>. The inlet portion also has a spring locking groove <NUM> to work with the connection assembly <NUM>.

In another embodiment of the present invention, modular respirator <NUM> comprises one or more sensing devices, wherein the sensing devices have a self-sustained controller and power supply. In one embodiment, the sensing device is a CO<NUM> measurement device, as CO<NUM> is one of the important parameters to determine if the user is over-breathing or not.

In one embodiment, air samples are picked up via the sensing pick-up assembly <NUM> as shown in <FIG>, where the sensing pick-up assembly is press-fitted in the connection assembly <NUM>. For examples, the said sensing pick-up assembly <NUM> is fitted in the connection assembly <NUM> that connects to the controlling unit <NUM>, where a sensor tubing is used to connect between a pressure sensor and the pick-up port in the sensing pick-up assembly <NUM>. The sensing pick-up assembly <NUM> can have more than one ports separated apart, and one of them can be used to pump out a small stream of air via a small pump located in the controlling unit <NUM> before feeding the sampled air to a CO<NUM> sensor.

Referring to <FIG> and <FIG>, the connection assembly <NUM> or push-fit connector consists of a socket <NUM> and a ring <NUM>. In one embodiment, the connection assembly <NUM> comprise a Quick Connect Interface and a Quick Connect Ring.

In one embodiment, the socket <NUM> has a spring loaded releasing bush that engages with the ring <NUM>. In the normal connected position, the spring <NUM> pushes to fall into the locking groove <NUM> on a stud <NUM> on the filter <NUM> or exhalation units <NUM>. Typically, the male push-fit connector comprises a stud <NUM> with a locking groove <NUM>. The female push-fit connector comprises a socket <NUM> have a spring <NUM> for engaging the locking groove <NUM>, and a ring <NUM> with one or more latches <NUM> to form spring loaded latches for manipulating the spring <NUM> and the locking groove <NUM>.

Referring to <FIG>, the air flow generator <NUM> comprises of a blower unit <NUM>, a controlling unit <NUM> holding the electronics and the power unit <NUM>, and an adjustable neck band <NUM>. Optionally, there is also provided a head band. In one preferred embodiment of the present invention, there are electronics for sensing / analytical purpose, such as flow, pressure and CO<NUM>. If flow sensor to fit with the blower unit <NUM>, the electrical cable runs from right side to left side as in the powered version.

The controlling unit <NUM> as shown in <FIG> comprises a casing <NUM> housing the printed circuit board, the electronic components and batteries. The casing <NUM> in turn consists of a first shell portion and a second shell portion that is connected together by releasable joining means such as snap-fit joint, or screw joint. The casing <NUM> of the controlling unit <NUM> is adapted to accommodate a power unit <NUM>, a controller, a sensor system and a Keypad/LED controlling system. In one preferred embodiment, the power unit <NUM> comprises a rechargeable battery pack, and there is another circuit for charging control.

The small end connects to one of the male and female push-fit connectors of the connection assembly <NUM> via the pipe thread connection.

The controller controls the blower unit <NUM> to deliver the required air pressure and flow to the mask assembly <NUM>, and the power unit <NUM> is used as an energy storage means to provide the electrical power to the power assembly. A breath responsive flow control algorithm is made to control the air flow to the mask assembly <NUM>. The breathing resistance is controlled by the peak pressure in the mask assembly <NUM>. When the peak pressure is negative, breathing resistance is present. For producing higher resistance, the blower will need to product less flow. The breathing resistance is set in multiple levels, where the higher value in level represents higher resistance. For example, setting "<NUM>" simulates normal breathing. Setting "-" provides a boosted flow trying to maintain positive pressure in the mask assembly <NUM>, thus providing a setting for the best air pollution protection among all other settings.

The controller also performs battery charging and battery state of charge indication. Preferably, charging voltage can be in a range of 5V to 15V, with slower charging time at 5V and faster charging time from <NUM>. In another embodiment, the charging current can linearly be increased with the increase of the input voltage. Preferably, charging voltage can be in a range of 5V to 12V, with slower charging time at 5V and faster charging time at 12V increasing linearly with the voltage.

In another embodiment, the controlling unit <NUM> further comprises a communication means for sending data such as breathing data to a data analytical device such as a smartphone or a smart wristband. The data is logged and can be displayed via the analytical device. The analytical device typically has more processing power and may receive data from other sources, such as the global positioning system, thermometer, barometer, hygrometer, etc. The analytical device may send signal to control the modular respirator <NUM>.

Since data and control signal may be communicated between the modular respirator <NUM>, a number of secured measure will be implemented to ensure the integrity of the data. In one embodiment, the controlling unit <NUM> comprises a cryptographic circuit to maintain a secured channel for communicating data.

In one preferred embodiment, at least one pressure sensor is mounted on the sensor system, which is used to sense the mask pressure via the said air passage in the exhalation unit. In another embodiment, a flow sensor can be used to measure flow and tidal volume.

The Keypad/LED controller controls the keypad / LED <NUM> disposed on the surface of the casing <NUM>. The keypad / LEDs can serve as user interfaces.

In one embodiment, there is no blower unit <NUM> provided in the modular respirator <NUM>. However, the modular respirator <NUM> comprises a controlling unit for receiving and analysing data from different sensing device on the modular respirator. In this setting, the modular respirator <NUM> may provide a more sophisticated display unit in place of the blower unit <NUM> for displaying the information graphically. The electric cables for the sensing devices and the display may be embedded in the neck band assembly <NUM>.

Referring <FIG>, the neck band assembly <NUM> also has one of the male push-fit connector and female push-fit connector of the connection assembly <NUM> adapted to connect the filter unit <NUM> or the exhalation unit <NUM> together while forming an air-tight seal in between. In this position, the spring loaded latches <NUM> will be locked in the locking groove <NUM> accordingly. When the connection ring <NUM> rotates or pushes, the spring loaded latches <NUM> comes out of the locking groove <NUM>, thus quickly disconnects from the filter unit <NUM> or exhalation units <NUM>. The connection assembly <NUM> is attached to the air flow generator <NUM> or neck band assembly <NUM> preferably by pipe thread connection.

The neck band assembly <NUM> consists of neck band <NUM> having a stub or mating unit <NUM> at each extremity of the neck band assembly <NUM>. The neck band assemble <NUM> also comprises an adjusting means <NUM> for adjusting the inhalation resistance. In one embodiment, the adjusting means <NUM> is a dial provided on a mating unit or stub <NUM> connected to the filter unit <NUM>.

In one preferred embodiment, the mating unit / stub <NUM> comprises of pipe thread connection to engage with the pipe thread on one of the male and female push-fit connectors or socket <NUM>.

When the neck band assembly <NUM> is in use as part of the system, the modular respirator <NUM> is operated in non-powered mode. The modular respirator <NUM> may provide a multi-level breathing resistance settings, and it also provides a smaller, lighter version of APRs.

In one embodiment, the adjusting means <NUM> is a dial. When the dial is in its most opened position, the inhalation resistance is the minimum. In one preferred embodiment, there are six step settings, with each step change about <NUM><NUM> in cross-section area, and the minimum opening is around <NUM><NUM>. The dial has an arris at each step to provide a feel of the step and also to help hold the said dial position. The neck band <NUM> is adjustable in length. When the neck band <NUM> has been adjusted to a desired position, it remains in tightened position without becoming loose.

In another embodiment, the neck band <NUM>, comprises a sleeve <NUM>. The sleeve <NUM> of the neck band <NUM> is adapted to having one or more coiled cables to fit therethrough. The sleeve <NUM> which is also elastic. In another embodiment, the neck band <NUM> or head band is made of elastic material,.

Referring to <FIG>, the blower unit <NUM> comprises a blower casing <NUM> housing an electric blower <NUM>. The blower casing <NUM> comprising a top shell <NUM> and a bottom shell <NUM> releasably joined together by one or more releasably joining means such as snap-fit joint, or screw joint.

The blower casing <NUM> is adapted to accommodate a pre-filter <NUM>. A filter cover <NUM> is provided on the blower casing <NUM> to cover the pre-filter <NUM>. The pre-filter <NUM> is to protect the blower <NUM> from dust and dirt in the environment. Preferably, the pre-filter <NUM> efficiency is over <NUM>% for particular size of over <NUM>. The pre-filter <NUM> may optionally have nuisance level harmful gas absorption capability, such as by impregnating activated carbon with the filter media of the pre-filter.

Inside the blower unit <NUM>, there is provided an electric blower <NUM> comprising a motor <NUM> and an impeller <NUM>. In one embodiment, the motor <NUM> and an impeller <NUM> are encased in a protective casing comprises a front shell <NUM> and a rear shell <NUM>. In one embodiment, the motor <NUM> and impeller <NUM> will be assembled together, then the subassembly will be inserted into front shell <NUM>. Finally, the rear case <NUM> will be put on.

In one embodiment, the motor <NUM> is a brushless direct current (BLDC) motor. Preferably, the BLDC motor is sensorless. The stator <NUM> of the motor is in a cylindrical shape wound with a number of coils, e.g. six. In order to facilitate the winding process, a number of protruding ribs <NUM> are provided on the stator <NUM>. In one embodiment, there are six protruding ribs <NUM> disposed on the stator <NUM>. As opposed to the way from the prior art, where the ribs are located along both ends and inner wall of the core, this design has the ribs located along both ends and outer surface of the core. The current design will relieve precious space of the inner wall area, thus leaving more room for the winding. This is advantageous for a smaller core, where the width of the ribs can occupy one to two turns of winding space per layer.

On the outer surface of the motor <NUM>, there is provided a number of vane <NUM> to direct the air flow around the motor. The vanes <NUM> are also adapted to support the motor <NUM> inside housing of the electric blower <NUM> such that the motor will securely fitted inside the blower casing. On one of the shells of the housing of the electric blower <NUM>, there is provided an opening adapted to allow the wiring pass therethrough.

In one embodiment, the impeller <NUM> comprises a conical stem <NUM> have a plurality of impeller fans <NUM> extending outwardly from the conical stem <NUM>. The impeller <NUM> hence is also substantially conical.

In operation, the impeller <NUM> create a centrifugal motion pushing the air outwards to the wall of the front shell <NUM>. The front shell <NUM> confines the flow of the air towards the motor <NUM> and the rear shell <NUM>. The air flow leaving the impeller with a whirlwind motion. When the whirlwind gas moves towards the vanes <NUM> of the motor <NUM>. In one embodiment, the vanes <NUM> is inclined in an opposite direction of the impeller fans <NUM> such that the vanes <NUM> correct the whirlwind motion to a straight motion directed to the rear shell <NUM>. The rear shell <NUM> comprises a plurality of apertures for the gas to escape.

In one embodiment, the impeller is so designed that the airflow direction can be reversed according to the rotation direction, i.e. to draw air from the blower inlet in normal mode and to drawing air from the mask in reversed mode. Thus, when the impeller rotates to draw air from the mask, the wearer needs to breathe harder to overcome the reversed airflow from the blower, creating a breathing resistance to the wearer. By varying the reversed airflow, variable breathing resistance can be achieved.

The speed range of the blower can vary widely. During exhalation phase, the speed can be very low, down to <NUM>,000rpm. In the inhalation phase, the speed can go up to <NUM>,000rpm or even more. Higher top speed tends to make the blower smaller. However, when the speed is too high, it stresses the bearings, and may generate more noise. In one embodiment, the operation speed of the blower will be between <NUM>,<NUM> to <NUM>,000rpm.

The contour of casing of the electric blower <NUM> as shown in <FIG> makes the flow more laminar or less turbulent. Further, the shape and arrangement of the impeller fans of the present invention can reduce the fan torque at a given fan speed for a range of fan pressure and flow product. As a result, the whole airpath of the respirator <NUM> (between blower outlet <NUM> to mask inlet <NUM>, between air inlet to fan) is short, thus by design it lowers pressure loss, leading to energy saving, less motor speed for a given flow thus quieter.

In another embodiment, the stator <NUM> of the motor <NUM> is a ferrite core, which produces very low iron loss (eddy current) and hysteresis loss compared with silicon steel lamination. The elongated design also promotes low inertia that reduces the power demand at each inhalation motor acceleration phase.

In one embodiment, the rotor of the motor <NUM> will be accurately balanced in production. Further, a smaller rotor will be used to reduce the amount of imbalance. There is potting on the motor core windings, to reduce the windings vibration.

In another embodiment, the inlet filters or spaces in inlet compartment can be used to insert a silencer or noise damping material to reduce noise level.

In one embodiment, the blower average power is kept in a low level most of the time, as exhalation requires minimum power. Therefore the heat produced can be sufficient dissipated over the entire motor mass. The elongate shape of the motor <NUM>, and the air flows just outside the wingdings separate by a thin wall. So it will help to take the heat way further.

The double casing of the motor <NUM> and the impeller <NUM> block out significant amount of operational noise created by the gas motion. In one embodiment, there is provided rubber cushion / suspension between the blower and blower housing. For example, the front shell <NUM> and rear shell <NUM> has silicone seal or pad <NUM> around the motor <NUM> to reduce operational vibration.

At one end of the blower unit <NUM>, there is provided pipe threads for sealing connect to a connection assembly <NUM>. On the other end of the blower unit <NUM> there is provided an adjustable neck band <NUM>, and optionally a head band.

In one embodiment as shown in <FIG>, the adjustable neck band <NUM> or head band may comprise a cable <NUM> that provide electrical power to the blower. In one embodiment, the cable <NUM> is a coiled cable which is compressible and extensible. In one embodiment, the neck band <NUM> or head band comprises an inner sleeve <NUM>, an outer sleeve <NUM> and a latch <NUM>.

The neck band <NUM> / head band is able to retract and extend to suit the size of the necks and heads of most users, and the adjustment can be done easily, where the position can be latched once the adjustment is satisfactory. The neck band <NUM> / head band can be positioned on top the head, or on back of the neck, or anywhere in between.

In another embodiment as shown in <FIG>, an inhalation one-way valve is fitted to the end of the thread connector <NUM> to stop breathed air going back to the filter unit <NUM>.

In another embodiment as shown in <FIG>, <FIG>, and <FIG>, a drain valve is added at the bottom of the mask <NUM> to allow accumulated condensation or sweat to drain away. The position of the valve makes minimum impact on the general appearance of the mask.

Referring to <FIG>, another preferred embodiment of the present invention is presented. In this embodiment of the present invention, there is provided a modular respirator <NUM> comprising an elongate filter unit <NUM> having a filter push-fit connector <NUM>, a filter outlet thread connector <NUM>. The modular respirator <NUM> comprises an elongate controlling unit <NUM> having a thread connector at both ends of the unit.

The modular respirator <NUM> further comprises a mask assembly <NUM> having a mask for covering the oral and nasal passage of a user, at least one exhalation assembly <NUM>, a mask inlet tread connector <NUM> at one end of the mask, a mask quick connect interface <NUM> at an opposite end of the mask, wherein the mask inlet is releasably fastened to the controlling unit outlet <NUM>, and the mask quick connect interface <NUM> is releasably fastened to the filter push-fit connector <NUM>.

The modular respirator <NUM> further comprising a blower unit <NUM> located at the back of the neck, having a thread connector <NUM> at each end of the unit, a blower <NUM>, an electric cable <NUM> and an air pipe <NUM>. The blower unit <NUM> connects between the filter unit <NUM> and the control unit <NUM>.

In one embodiment as shown in <FIG>, the filter unit <NUM> has a replaceable rectangular filter element and a pre-filter.

In one embodiment as shown in <FIG> and <FIG>, the mask quick connector <NUM> has a blocking end to prevent air from entering into the mask. When the blower <NUM> runs, air comes in from the filter unit <NUM>, entering the blower unit <NUM>, then the control unit <NUM> before entering the mask assembly <NUM>. Donning and doffing respirator <NUM> can be easily done via the quick connector <NUM>.

In one embodiment as shown in <FIG>, the air pipe <NUM> is made of rubber having a section of bellows at each end which is compressible and extensible. The elastic nature of the air pipe <NUM> also functions as part of the fastening mechanism to secure the respirator <NUM> around the head.

In one embodiment as shown in <FIG> and <FIG>, the electric cable <NUM> is a coiled cable which is compressible and extensible.

In one embodiment as shown in <FIG>, <FIG>, the controlling unit <NUM> comprises a control PCB, a battery <NUM>, and a casing having a sealed air path between the inlet thread connector <NUM> and the outlet thread connector <NUM> of the unit.

Referring to <FIG>, the thread connector <NUM> can be also a push-fit connector <NUM>; and likewise the thread connector <NUM> can be also a quick connect interface <NUM>.

In one embodiment, the controlling unit <NUM> has a thread connector at an inlet end and a push-fit connector at an outlet end; the mask assembly has a quick connect interface at each end of the mask. The air pipe <NUM> may comprise a thread connector assembly adapted to adjust a length of the air pipe and to releasably fasten to the controlling unit and the filter unit.

In another embodiment, the mask inlet connector can be a thread connector or a Quick Connect (push-fit) connector; an adjustable threaded connector assembly to adjust the length of the air pipe.

The respirator described in this embodiment is more suitable for heavy dust environment, such as in industrial settings.

The present invention can be utilised in many applications, including but not limited to:.

Reference is now made to <FIG>. In one embodiment of the present invention, there is provided a respirator <NUM> having a single string strap for replacing the pull-over bands <NUM>. In this embodiment, the respirator <NUM> comprising a mask <NUM>, a left-side assembly <NUM>, a right-side assembly <NUM>, and a single string strap assembly <NUM>. The left-side assembly <NUM> is connected to the right-side assembly <NUM> through a cable assembly <NUM> at one end, and a mask assembly <NUM> at the other end.

In one embodiment, the mask assembly <NUM> comprises a bridge structure <NUM> linking the mask body with an air passing channel <NUM>. The bridge structure <NUM> is disposed at a location approximately along the line intersecting with the centre of gravity of the mask assembly <NUM>. Preferably, a bridge structure <NUM> is adapted to form a loop with an air passing channel <NUM> and the mask body.

The single string strap assembly <NUM> comprises a single string <NUM>, a pad <NUM>, a latch <NUM>,.

On the left-side assembly <NUM> and the right-side assembly <NUM>, there are hook <NUM> through which the single string <NUM> passes. In one preferred embodiment, the single string <NUM> passes through a hook <NUM> on the left-side assembly <NUM>, then a loop formed by a bridge structure <NUM> and a left air passing channel <NUM>, then a head pad <NUM>, then another loop formed by a bridge structure <NUM> and a right air passing channel <NUM>, and then another hook <NUM> on the right-side assembly <NUM>.

Hence, the single string strap assembly <NUM> works in such a way that, the single string forms a closed loop with one end with the head pad <NUM> adapted to be placed on the back of a user's head, and the other end being located at the back of the user's neck. When two opposite ends of the single string <NUM> are pulled through latch <NUM>, a combined pulling force acts on the line intersecting the centre of gravity of the mask assembly <NUM>. As a consequence, the pulling force of the single string <NUM> turns to an action of pushing the mask body to the user's face. In one embodiment, when the pulling force does not act on the line intersecting the centre of gravity of the mask assembly, the pushing force induced on the mask body would not be evenly distributed. Then two separate strings would be needed, as would most conventional masks.

Further, once the single string <NUM> is tightened, it induces a pulling force to pull the left-side assembly <NUM> and the right-side assembly <NUM>. Hence the single string strap assembly <NUM> of an embodiment of the present invention is adapted to work as if there are <NUM> separate fastening strings, thus greatly simplifies the fastening system. towards the neck, acting similarly to a separate fastening string.

In one embodiment of the respirator <NUM>, the cable assembly <NUM> has a coiled cable <NUM>. In another embodiment of the respirator <NUM>, the cable assembly <NUM> can be replaced by an adjustable band as shown in <FIG>. In yet another embodiment of the respirator <NUM>, there is no cable assembly nor adjustable band linking between the left-side assembly <NUM> and the right-side assembly <NUM>.

In another embodiment, the hooks <NUM> of the respirator <NUM> can be located at other locations of the left-side assembly <NUM> and the right-side assembly <NUM>.

In an embodiment where the left-side assembly <NUM> and the right-side assembly <NUM> are too heavy, a separate supporting string or strap may be needed for each of the left-side assembly <NUM> and the right-side assembly <NUM> to secure the respirator <NUM> on the head
In a preferred embodiment, the hook <NUM> is a separate part that can be secured to the casing of the left-side assembly <NUM> and right-side assembly <NUM> as shown in <FIG>. The hook <NUM> may be positioned in a concealed location so that it will not scratch the cheek of the user. In one embodiment as shown in <FIG>, the hook <NUM> is adapted to be secured to the respirator using screw. The screw that is used to tighten the hook <NUM> can also be used to tighten the casing that the hook is attached to.

In one embodiment as shown in <FIG>, there is provided a thread connector assembly <NUM> for replacing the thread connector <NUM>. The thread connector assembly <NUM> comprises a threaded adjusting ring <NUM> coupled with a bush collar <NUM> adapted to hold an adjustable number of corrugations. The bush collar in <FIG> has an opening at the end facing the blower, so air can pass through. By adjusting the effective length of an air pipe can achieve a good fit of the respirator <NUM> according to the neck size of the user. By doing so, the air pipe works more effectively as part of the fastening mechanism for the respirator.

<FIG> shows the bellows <NUM> in the relaxed state, <FIG> shows the bellows <NUM> in compressed state, and <FIG> shows the bellows <NUM> in stretched state.

Further, in one embodiment of the present invention, it is used for asthma patients. By restricting breathing, an embodiment of the present invention can be beneficial to help asthma patients correct their "bad" breathing habit and breathe less air, and eventually reduce the attacks and improve their wellbeing. In an embodiment of the present invention, it can reduce the chances for an asthma attack if patients wear it to do exercise.

In one embodiment of the present invention, it is differed to the traditional respirator concept that the traditional respirator is design for air pollution protection only.

Claim 1:
A multi-purpose modular respirator (<NUM>) comprising:
an elongate filter unit (<NUM>) having a filter inlet (<NUM>), a filter outlet (<NUM>), and a replaceable fluid filter (<NUM>) for filtering pollutants within the fluid;
an elongate exhaust unit (<NUM>) having an exhaust inlet (<NUM>), an exhaust outlet (<NUM>), and one or more one-way valves (<NUM>);
an air flow generator (<NUM>) or a neck band assembly (<NUM>), said neck band assembly comprising an adjusting means (<NUM>) for adjusting the inhalation resistance;
a mask assembly (<NUM>) having a mask (<NUM>) for covering the oral and nasal passage of a user, a mask inlet (<NUM>) at one end of the mask, a mask outlet (<NUM>) at an opposite end of the mask, wherein the mask inlet (<NUM>) is releasably fastened to the filter outlet (<NUM>), and the mask outlet (<NUM>) is releasably fastened to the exhaust inlet (<NUM>);
wherein
the filter unit (<NUM>) is located around an anterior triangle on one side of a neck and the exhaust unit (<NUM>) is located around an anterior triangle on an opposite side of the neck, wherein the filter unit (<NUM>), the mask (<NUM>) and the exhaust unit (<NUM>) jointly form a tightly sealed passage for fluid to pass therethrough;
wherein the filter inlet is connected to the air flow generator (<NUM>) or the neck band assembly (<NUM>) via a push-fit connector with a spring-loaded ring; and
wherein the exhaust unit is connected to the air flow generator (<NUM>) or the neck band assembly (<NUM>) via a push-fit connector with a spring-loaded ring.