US20210275714A1

US20210275714A1 - Uvc anti-microbial breathing sterilizing modules, masks and devices

Info

Publication number: US20210275714A1
Application number: US16/898,679
Authority: US
Inventors: Stephen Almeida; James Kerr
Original assignee: World Hygienic LLC
Current assignee: World Hygienic LLC
Priority date: 2020-03-04
Filing date: 2020-06-11
Publication date: 2021-09-09
Also published as: WO2023015109A1; US20210361818A1; US11690929B2

Abstract

The present application for patent is in the field of anti-microbial breathing apparatus. More specifically the present application for patent is in the field of anti-microbial sterilizing modules and apparatus wherein the apparatus comprise a sterilization module which contains UVC, UVA/B, and/or blue light sanitizing radiation emitting components which sterilize the air passing through the sterilizing module to be breathed prior to the air entering the body of the user. The disclosure optionally includes the use of filters, electronically charged screens. fans, and intake and outflow valves.

Description

This application claims priority of the filing date of U.S. Provisional Patent Application Ser. No. 62/985,155 filed 4 Mar. 2020, entitled “UVC ANTI-MICROBIAL MASK AND MODULES” which application is incorporated by reference herein in its entirety.

FIELD OF INVENTION

The present application for patent is in the field of anti-microbial breathing apparatus. More specifically the present application for patent is in the field of anti-microbial sterilizing modules and apparatus wherein the apparatus comprise a sterilization module which contains UVC, UVA/B, and/or blue light sanitizing radiation emitting components which sterilize the air passing through the sterilizing module to be breathed prior to the air entering the body of the user.

BACKGROUND

Microbial masks utilize filter systems to protect the user from outside bacteria, virus, and microbes. Currently available filtration-based mask systems range from non-medical cloth masks, to surgical or medical masks to N95 masks. Non-medical cloth masks are often home-made and often recommended through such conduits as the media as being a good, safe preventative measure against such viruses as Covid-19 but should only be used as a last resort. In addition the fit is never good so that leakage of air from the outside through the sides of the mask making these mask a problem, as well as giving the user a false sense of safety which could result in the user taking risks that they would not ordinarily take. Surgical or medical masks are a step up from cloth masks and are generally disposable and considered to be barriers to large aerosol particles that contain viruses. The N95 masks are considered to be the best with a “tight fit” although significant training is necessary to ensure a tight fit. (See FIG. 2). They are rated to screen out 95% of small airborne particles such as those suspended in mists that carrier a virus. As can be seen the best masks only filter our 95% of the infectious particles. While there are masks that are rated to remove 99+% of particles from the air, they can still allow viruses through (See FIG. 1). Utilizing a valve on these masks is also ineffective as the lack of seal will not adequately activate a valve.
More effective masks utilize a silicone seal around the mouth and nose and generally have two intake filters with one-way valves and an exhaust valve with no filter for exhale. They can also be full face to cover the eyes for better protection. There are several problems with this design. One, the mask protects the user from outside microbes via the intake filters, but it does not protect the outside population from an infected user. Two, microbes will collect on the outside of the filter which can contaminate the user by physical contact with the mask. Three, in the case of filter imperfections, there is no redundancy system to prevent contamination of the user.
It is well documented that filters do not act as sieves. The filters used in modern surgical masks and respirators are considered “fibrous” in nature—constructed from flat, nonwoven mats of fine fibers. Fiber diameter, porosity (the ratio of open space to fibers) and filter thickness all play a role in how well a filter collects particles. In all fibrous filters, three “mechanical” collection mechanisms operate to capture particles: inertial impaction, interception, and diffusion. Inertial impaction and interception are the mechanisms responsible for collecting larger particles, while diffusion is the mechanism responsible for collecting smaller particles. In some fibrous filters constructed from charged fibers, an additional mechanism of electrostatic attraction also operates. This mechanism aids in the collection of both larger and smaller particle sizes. This latter mechanism is very important to filtering facepiece respirator filters that meet the stringent NIOSH filter efficiency and breathing resistance requirements because it enhances particle collection without increasing breathing resistance.
It is also well known that an increase in respiration rated reduces the effectiveness of filtration as the velocity of the particle entering the mask is increased thereby altering the usefulness of some of the mechanism by which the filter works. (See FIG. 3).
The best filters commercially available are considered to be HEPA filters, which remove particles down to 0.1 μ. While helpful, it has been found that certain viruses, such as Cociv-19 can range below 0.1 μ to about 0.06 μ rendering such filter as ineffective.
Based on the foregoing it is an unmet need to obtain improved anti-microbial breathing apparatus that is more effective and efficient and address the shortcomings of the currently available breathing system, in particular, addressing the viral particles that do get through the system.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a chart the particle blocking capability of various masks.

FIG. 2 shows a chart of the fit ability of various masks.

FIG. 3 shows a chart of the increase in particle penetration as a function of respiratory volume.

FIG. 4A shows a front view and cutaway of an embodiment of the current disclosure.

FIG. 4B shows a side view cutaway of an embodiment of the current disclosure.

FIG. 5 shows an embodiment of the attachment mechanism for removably attaching a module of the current disclosure to a breathing apparatus.

FIG. 6 shows an embodiment of the current disclosure, including filters.

FIG. 7 shows an embodiment of the current disclosure including sanitizing bulbs.

FIG. 8A shows a side view cutaway of a cylindrical embodiment of the current disclosure further utilizing air valves.

FIG. 8B shows an end view of the cylindrical embodiment with

circular baffles

66 and 67.

FIG. 9 shows an embodiment of the current disclosure utilizing to aid in the intake of ambient air as well as filters and removable reflective insert.

FIG. 10 shows an embodiment of the current disclosure wherein modules are removably attached to a breathing apparatus.

SUMMARY OF THE DISCLOSURE

It is an object of the current invention to overcome the deficiencies commonly associated with the prior art as discussed above and provide sterilizing modules, devices and methods that eliminate or deactivate undesirable pathogenic microorganisms from entering the body of a user of the devices.
In a first embodiment, disclosed and claimed herein are anti-microbial sterilizing modules comprising at least one sterilizing radiation emitting component, wherein the sterilizing module is configured to be removably attached to a breathing device.
In a second embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of the above embodiment wherein the breathing device to which the sterilizing module is removably attached is a wearable mask.
In a third embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of the any of the above embodiments wherein the sterilization module comprises an air intake port through which ambient air may enter the sterilizing module, an elongated path internal to the sterilizing module through which the ambient air may travel, at least one sterilizing radiation emitting component situated internal to the sterilizing module and, an exit port through which the ambient air may enter the mask, wherein the sterilizing radiation emitting component irradiates the ambient air when travelling through the sterilizing module.
In a fourth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments wherein the at least one sterilizing radiation emitting component emits blue light, UV light, UVC light or combinations thereof and the interior of the sterilizing module through which air passes is fully or partially reflective of the sterilizing radiation.
In a fifth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments further comprising filters situated on or in the sterilizing module, on or in the breathing apparatus, or both, and wherein the filters are optionally replaceable.
In a sixth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments further comprising intake and outflow valves.
In a seventh embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments wherein the sterilizing module is self-powered and configured to be powered externally.
In an eighth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments wherein the elongated path is a linear path with optional 180 corner bends, a circular path wherein air that is taken in flows around circular baffles, a spiral path or a rectangular path having at least one intake and/or at least one outflow valve which regulates the intake and outflow of air in the module.
In a ninth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments wherein baffles made of UVC transparent material are arranged internal to the sterilizing module which are configured to direct the intake air to move through the sterilizing module, wherein the baffles allow UVC to pass through the baffles when directing the air intake through the sterilizing module.
In a tenth embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments further comprising a metallic screen situated internal to the sterilization module.
In a eleventh embodiment, disclosed and claimed herein are anti-microbial sterilizing breathing modules of any of the above embodiments further comprising at least one baffle situated internal or external to the sterilizing module, configured to prevent sterilizing radiation from exiting the sterilizing module and further comprising a fan configured to move air into the sanitizing module.

DESCRIPTION OF THE INVENTION

As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.
As used herein, the conjunction “and” is intended to be inclusive and the conjunction “or” is not intended to be exclusive unless otherwise indicated. For example, the phrase “or, alternatively” is intended to be exclusive.
As used herein, the term “and/or” refers to any combination of the foregoing elements including using a single element.
As used herein the term “breathing apparatus” includes such devices as masks, ventilators, breathing tubes, of other devices that aid in assisting the deliverance of air to a person or animal.
As used herein the term UVB refers to electromagnetic radiation with wavelengths ranging between about 280-315 nanometers, inclusively.
As used herein the term UVC refers to electromagnetic radiation with wavelengths ranging between 100-280 nanometers, inclusively.
In response to the long-needed improvement of personal protection equipment, especially the need for improved breathing apparatus to combat past, present, and future viruses and other pathogens, a new inventive sterilizing module is provided for the destructive and/or at least deactivation of such pathogens. The innovative sterilization module which receives ambient air from the outside of the sterilizing module through one or more intake ports and through the action of the user's breathing, pulls the air through an elongated path in the sterilizing module and out of the sterilizing module through one or more exit ports. In some embodiments, where necessary, a mechanical assist may be present which helps to pull or push the air into the sterilizing module and through the sterilizing module out to the user. The now sterilized air passed out the at least one exit port of the sanitizing module and enters the remainder of the breathing apparatuses such as, for example, a mask.
The sterilization module contains one or more electromagnetic radiation emitting components, such as, for example, LEDs, mercury vapor fluorescent bulbs, filament bulbs and lasers.
Since it is well known that pathogens, such as, for example, viruses, bacteria, molds, mildews and the like, can be destroyed or at least deactivated when exposed to certain wavelengths of electromagnetic radiation, one or more radiation emitting components are arranged in various positions internal to, that is throughout the interior of, the sterilizing module. The radiation emitting components can emit blue light radiation, UVB radiation or UVC radiation each of which is known to destroy or deactivate various pathogens. The sterilizing module may contain components that only emit in one sterilizing radiation range, or there can be a combination of components that emit in any of the blue, UVB and UVC radiation ranges.
As the air passes through one or more intake ports and through the sterilization module, the radiation emitting components sterilize the air prior to exiting the sterilization module and entering the remainder of the breathing device and prior to entering the body of the user. The devices are configured to be useful for either a human or an animal.
Breathing apparatuses useful for the current disclosure include, for example, masks, ventilators, breathing tubes, of other devices that aid in assisting the deliverance of air to a person or animal. Each of these apparatuses useful for the current disclosure are configures to be removably attached to the currently disclosed sterilizing modules. In some embodiments the sterilizing module is removably attached to a mask, wherein the mask is wearable so that in toto the weight of the combination mask and sterilizing module are less than about 2 pounds. The sterilizing module is detachable which allows for cleaning, replacement, maintenance, repair or other desired activity.
The sterilizing module is configured to have an elongated path through which air flows and becomes sanitized, as pathogens are destroyed or deactivated. The path may take a variety of configurations such as, for example a straight passageway or a passageway the runs straight then bends at a 180° angle, the angle being anywhere along the axis of the passageway (See FIG. 4). The straight passageway may have bends at more than one angle in order to provide extended distances through which the air travels. The angles can be any angle, such as, for example, 45°, 90°, 135°, 180° or the like. Increased pathway distances provide an increase in the amount of sanitizing radiation available for sanitizing the incoming and exiting air. The elongated path may also be a combination of any of the above described pathways. In any of these configurations sanitizing radiation components are situated internal to the pathway and throughout the length of the elongated pathway. The module may be of any suitable 3-dimensional shape, such as, for example, cubic, cuboid, cylindrical, prismatic, conic, pyramidal and the like. The elongated path of the sterilizing module may take on other configurations such as, for example, circular, spiral, straight, as well as combinations.
The interior of the sterilizing module is fully or partially reflective of the sterilizing radiation. The sterilizing module may be fabricated from sanitizing radiation reflective material or the interior of the sterilizing module may have sanitizing radiation reflective material applied to the interior surfaces of the sterilizing module. Application may be CVD, coated or laminated and the like. Materials suitable for reflecting sanitizing radiation generally depend on the sanitizing radiation used. Materials that reflect blue and UVB radiation are well known in the industry, such as, for example, aluminum. Materials that reflect UVC radiation include aluminum foil, sputtered aluminum, stainless steel, chrome coating and e-PTFE (expanded Polytetrafluoroethylene). There is no limit to the layout of the elongated path in the sterilizing module. With the selected arrangement of baffles within the sterilizing module an infinite number of layouts may be obtained.
The sterilizing module may also contain one or more metal screens positioned throughout the interior of the sterilizing module. The metal screen is configured to capture droplets of moisture which can carry various pathogens. The screen can be configured in the sterilizing module to allow sanitizing radiation to expose the droplets and attack any pathogens present. The screen may also be fabricated from metals and alloys which are known to aid in the destruction, deactivation, or reduction in activity of pathogens.
The sterilizing modules may also include one or more filters of various types well known in the industry for filtration, such as, for example, filter material used in surgical masks and other filter material designed for microbial environments. The filters may be positioned at the front, back, or both and throughout both the sterilizing module and optionally through the remainder of the breathing apparatus to which the sterilizing module is removably attached. Additional filters may be included in the sterilizing modules that are capable of being electronically charged, such as, for example, metallic screens or screens that contain a layer of conductive materials such as, for example, metal, conductive polymers, graphene materials and the like. The screen may be made of materials which are reflective of the sanitizing radiation to allow the radiation to be directed throughout the module. It is known that in some cases viruses or other pathogens are transferred primarily through aerosol moisture. Electrified screens can attract aerosols which are generally known to carry a polarity. By charging a screen the aerosol particles can be attracted to the screen and remain there during operation helping to allow sanitization radiation to sanitize the droplets
The modules of the current disclosure may be configured to be disassemble for cleaning, component replacement, ease of storage or other purposes. The module may be made in various parts and assembled with gasket which are constructed to provide sealing of the module to prevent air from entering the module at any point other than the desired opening designed to direct the incoming air into the module for sanitization, or from air leaving he module at any point other than the exit provided by the module.
The sterilizing module also contains baffles at the intakes and outflow port which are configured to cover the openings of the ports to prevent sterilizing radiation from exiting the sterilization module.
The sterilization module may have least one intake valve, at least one outflow valve, or both to regulate the intake and outflow of air in the sterilization module. The intake valve is configured to open when air is taken in and closed when air is exhaled from the used. The outflow valve works in tandem with the intake valve so that when the user exhales, the outflow port opens to allow air to exit, while the intake valve closes. In certain embodiments only an outflow port is present. In this configuration, no air is allowed to enter through anywhere but the intake port or pots so that all inspired air is subject to sterilization.
In some embodiments a fan is present configured to aid in the intake of ambient air. The fan may also act as a positive laminar flow device which provides positive pressure so that the intake of air at the interface of a mask or other loosely fitted breathing devices is eliminated or significantly reduced.
The sterilizing module of the current disclosure is configured to be self-powering using batteries, rechargeable batteries, or other components well known in the art to provide self-powering. In some embodiments there may also be included electronic connection in those cases where external power is necessary, such as in an emergency. The module may further contain a power control configured to increase or decrease power to the sterilizing radiation emitting components of the sterilizing module thus providing weaker or stronger sterilizing radiation to air coming into and through the sterilization module. In certain environments there may be higher risks of infection so that higher amounts of sanitizing radiation is required.
Moving now to the Figures. FIG. 1 shows a chart which compares and contrasts the efficiency of filtering masks. As can be seen cloth masks filter about 28% of particles while surgical masks improve to about 80%. The best masks available are dust respirators which contain 2 large cartridges on each side and are heavy and unwieldly and are only 98-99.5% efficient. FIG. 2 shows the results of a number of tests performed to determine the ability of a mask to fit properly and not allow particles to enter the mask from the mask-user interface. Also, the chart shows how different people fit the same mask. Specific instructions are needed to get a fit. FIG. 3 shows the effect of heavy breathing on the efficacy of N95 mask, mask that are touted as the best masks available for consumer use. As can be seen, heavy breathing essentially doubles the number of particles that are allowed through. Couple than with an expected increase in particles entering from the mask-user interface, due to a less than perfect fit, and these masks in this situation are less than ideal.
FIG. 4 depicts one embodiment of the current disclosure. FIG. 4A is a front view of the anti-microbial sterilizing module 10. Ambient air 14 enters the interior of the module 11 through opening 12, which includes a UV blocking cover, not shown. UVC/UVB emitting LEDs 20 and blue light emitting LEDS 22 are positioned inside the module to sanitize the air as it passes though the module. An on/off switch 16 is positioned in the module to allow turning the module on and off. A hi/low switch is also positioned in the module to allow for manipulation of the strength of the sanitizing radiation chosen by the user to respond to varying conditions wherein there may be higher or lower risks of microbial contamination. In this manner the battery power from the battery 24 may be preserved. FIG. 4A provides a cut-away side view of the anti-microbial sanitizing module. Ambient air 14 enters the interior of the module 39 through portal 12, and around the UV blocking cover. The air passes around baffles 35 and through the internal path 38 while UVC/UVB/Blue radiation LEDs 30 irradiate and sanitize the air. The interior of the module is fully or partially fabricated from, or at least covered with, UVC/UVC/Blue radiation reflecting materials as described above. The sanitized air then exits the module through an exit port 32 which is configured to removably attached to any type of breathing apparatus suitable and configured to receive the module.
FIG. 5 is an embodiment of an attachment socket of the current disclosure wherein the exiting air 42 passes through an opening in the wall of the module 43 and through an opening in the attachment wing 44. In addition, FIG. 5 shows a baffle 12 which blocks sanitizing radiation from exiting the module while at the same time is offset to allow air to be taken in and let out.
FIG. 6 depicts a further embodiment of the current disclosure wherein filters are arranged in the module to in filtering out dust or other harmful particles including some microbial materials. As depicted, ambient air 46 passes through a filter 45, such as, for example, a HEPA filter, and into the interior of the module 47. More than one filter may be positioned in this embodiment. Again baffles 48 are present to increase the path of the air allowing increased residence time of the air to be exposed to sanitizing radiation from sanitizing-radiation emitting LEDs 49. The sanitized air may then optionally pass through 51 another filter 50 prior to entering the breathing device to which the module is removably attached. Again, more than one filter may position here. Also shown in FIG. 6 is the embodiment wherein a further filter is included 45A which is metal screen (filter) which is electronically charged.
FIG. 7 depicts another embodiment of the current disclosure. Ambient air 54 passes through one or more filters 52 into the interior 53 of the module. The air passes around baffles 55 and exits though an exit port 57. In this embodiment a sanitizing radiation lamp 56 is positioned to sanitize the air.
FIG. 8 depicts a cylindrical module of the current disclosure which also includes intake valves. FIG. 8A depicts a cutaway side view of the cylindrical embodiment wherein the ambient air 62 enters the sanitizing module 65 through air intake valves 60. The air then passes around circular baffles 66 and 67. The air is irradiated with sanitizing radiation from sanitizing-radiation emitting bulb 63. The bulbs are covered with radiation blocking caps 64 to prevent radiation from leaking outside the module. The sanitized air then exits the module through an exit port. FIG. 8B depicts an end view of the cylindrical embodiment showing the circular nature of the baffles and overall module configuration.
FIG. 9 depicts an embodiment of the current disclosure which includes a fan for aiding in the passage of ambient air into and through the module. Ambient air 76 is drawn into a cavity 73 by a fan 70. The air 77 then passes through a filter 72 into the interior of the module 71. The air then travels around baffles 75 while sanitizing radiation from LEDs 74 sanitize it. The sanitized air 81 then exits through a filter 79. The sanitizing module is powered by battery and electronics 80. In this embodiment the baffles 75 are an insert which can be removed for maintenance and other purposes.
FIG. 10 depicts a sanitizing breathing apparatus utilizing the sanitizing modules of the current disclosure. Two sanitizing modules 92 are removably attached to a breathing apparatus, in this case a mask for wearing on the face to cover nose and mouth. The mask includes straps 95 for application. The mask also has an optional filtering port.
As can be seen from the foregoing discussion and the figures the current disclosure can take on many configurations.

Claims

We claim:

1. An anti-microbial sterilizing module comprising at least one sterilizing radiation emitting component, wherein the module is configured to be removably attached to a breathing device.

2. The anti-microbial breathing module of claim 1, wherein the breathing device to which the module is removably attached is a wearable mask.

3. The module of claim 2 comprising:

a. At least one air intake port, through which ambient air may enter the module,

b. an elongated path internal to the module through which the ambient air may travel,

c. at least one sterilizing radiation emitting component situated internal to the module and,

d. at least one exit port through which the ambient air may enter the mask, wherein the sterilizing radiation emitting component irradiates the ambient air when travelling through the module.

4. The module of claim 3, wherein the at least one sterilizing radiation emitting component emits blue light, UV light, UVC light or combinations thereof and the interior of the sterilizing module through which air passes is fully or partially reflective of the sterilizing radiation.

5. The module of claim 4 further comprising at least one filter situated on or in the module, on or in the breathing apparatus, or both.

6. The module of claim 5 further comprising a filter comprised of a conductive metal wherein the filter comprised of a conductive metal is configured to be electrically chargeable.

7. The module of claim 4 further comprising intake and outflow valves.

8. The module of claim 4, wherein the sterilizing module is self-powered and configured to be powered externally.

9. The module of claim 5, wherein the at least one filter is replaceable.

10. The module of claim 3, wherein the elongated path is a linear path with optional 180 corner bends, a circular path wherein air that is taken in flows around circular baffles, a spiral path or a rectangular path.

11. The module of claim 4 further comprising a fan configured to move air into the sanitizing module.

12. The module of claim 4, wherein baffles made of UVC transparent material are arranged internal to the module which are configured to direct the intake air to move through the module, wherein the baffles allow UVC to pass through the baffles when directing the air intake through the module.

13. The module of claim 4 further comprising a metallic screen situated internal to the sterilization module wherein the metal screen is configured to be electrically chargeable.

14. The module of claim 4 further comprising at least one baffle situated internal or external to the module, configured to prevent sterilizing radiation from exiting the module.

15. The module of claim 4, further comprising at least one intake valve and at least one outflow valve.

16. The module of claim 4, further comprising a power control configured to increase or decrease power to the sterilizing radiation emitting components of the sterilizing module.

17. The module of claim 4 wherein the module is configured to allow disassembly.