ZA200501881B - Integrated respirator - Google Patents

Description

1 Integrated Respirator 3 This invention relates to a respirator. In particular it 4 relates to an integrated respirator that 1s suitable for use by aircrew so as to provide significant higher levels 6 of comfort, stability and user acceptability. 7 8 Aircrew can be exposed to nuclear, biolcgical and ’ 9 chemical (NBC) hazards in the course of their flying duties. Therefore, in order to negate the effects of 11 such NBC hazards any respiratory system as well as the 12 crews eyes must be protected against aerosols and gases 13 in the air. Additionally, the rest of the body of any 14 crew member must be protected against direct contact with

NBC agents in the form of liquid or solid particles. 16 . 17 Protection of respiratory systems, eyes and skin area 18 above the neck of aircrew is normally achieved by wearing 19 an integrated respirator. Typical integrated respirator known to those skilled in the art consists of, but are 21 not exclusively limited to, a head cowl or hood, an 22 oxygen mask, a breathing gas supply hose, a clear visor, 23 a neck seal and a shoulder cover that forms a leak-proof 24 assembly that fully encloses the head.

CONFIRMATION COPY

I Such respirators are specifically designed to either fit 2 over or under the users flying helmet.

Such designs have 3 a number of inherent problematic features.

In particular 4 the over the helmet designs are bulky, and are easily ruptured in wind blast and ejection forces exhibited 6 during emergency egress.

Furthermore, it is difficult to 7 interface the over the helmet designs with other 8 equipment that requires to be mounted with the users 9 flying helmet.

11 For these reasons the under helmet configuration has been 12 adopted by most aircrew.

There are two main types of 13 under helmet respirator known in the art.

The first type 14 is worn under the helmet assembly and forms a close fitting hood around the head with an integral visor 16 aperture and oxygen mask.

This respirator type has 17 several deficiencies the principal being that most users 18 experience feelings of isolation or, semi-claustrophobia, 19 and heat stress attributed to the hood hugging the head and being held firmly in place by the helmet. 21 22 A second limitation of this type of respirator is the 23 associated reduced sound attenuation performance of the 24 ear cup.

This 1s due to the respirator cowl fitting between the ear and the ear cup.

26 27 A further deficiency of these respirators is the fact 28 that the material used for the hood must stretch for 29 donning and deoffing.

Thereafter, the material must 300 conform to the profile of the user's head so as to 31 provide a suitable mounting surface for the helmet. 32 Bromo butyl rubber is an example of an elastic material 33 used in the manufacture of cowls for such respirators. 34 However, this material produces high levels of discomfort

1 when worn next to the skin while reducing the stability 2 of the helmet. 3 4 Head mounted respirators with potentially lower levels of ’ 5 discomfort are also available.

However, the materials 6 used to construct such respirators do not stretch and as 7 such the cowl shape 1s required to be manufactured from 8 several shaped sections that are stitched and/or bonded 9 together.

As a result these respirator designs are particularly prone to leakage through the stitched and 11 bonded seams. 12 13 Another type of under helmet respirator known to those 14 skilled in the art employs comfort padding and communication system ear cups on the inside surface of 16 the cowl.

This arrangement allows air movement inside 17 the cowl reducing the thermal stress.

In addition, as 18 the ear cups are in direct contact with the head this 19 results in improved levels of sound attenuation.

The major disadvantages of this type of respirator is the 21 difficulty experienced in getting the ear cups correctly 22 positioned inside the cowl and the requirement for an 23 increased number of leak proof feed through apertures 24 such as ear cup cableforms and comfort pad to suspension system fastenings.

This results in unacceptable donning 26 times and an increased potential for faults leading to 27 leakage. 28 29 It is an object of an aspect of the present invention to provide an integrated respirator that provides a high 31 level of comfort, helmet stability and user acceptability 32 by being designed and constructed so as tc reduce direct 33 contact with a user’s head sc rendering the respirator 34 easy for a user to don and doff.

2 According to & first aspect of the present invention 3 there is provided an integrated respirator that provides

4 an airtight barrier for a user's head comprising a first . 5 rigid helmet and a flexible cowl having an airtight neck

6 seal, wherein the first rigid helmet defines an access

7 aperture suitable for locating directly on a user's head

8 and the flexible cowl is sealably fixed to the first

9 rigid helmet so providing a physical barrier for the access aperture while forming an airtight seal with a

11 user's neck.

12

13 Most preferably the first rigid helmet and the flexible

14 cowl comprises material that protects against nuclear,

chemical and biological hazards.

16

17 Preferably the flexible cowl completely encloses the

18 first rigid helmet.

Alternatively, the flexible cowl is

19 connected to the periphery of the access aperture.

In a further alternative the flexible cowl connects to an

21 inner surface of the first rigid helmet.

22

23 Most preferably the first rigid helmet provides a tight

24 fit with the user's head.

26 Optionally the integrated respirator further comprises a

27 hood that is fixed to the first rigid helmet so providing

28 a physical barrier for the flexible cowl thus improving ’ 29 the fire proof, snag proof and windblast proof properties } 30 of the integrated respirator.

31

32 Preferably the flexible cowl comprises a visor aperture,

33 an oxygen mask location area, a visor mist air supply and

34 a pressure release valve.

2 Preferably the integrated respirator further comprises a 3 second rigid helmet suitable for locating over the first 4 rigid helmet, an oxygen mask and a first visor. . 5 6 Preferably the oxygen mask location area comprises a 7 plurality of apertures suitable for receiving one or more § component parts of the oxygen mask when the oxygen mask 9 is located within the oxygen mask location area.

Alternatively, the oxygen mask location area comprises a 11 single aperture suitable for receiving the oxygen mask. 12 13 Most preferably the oxygen mask comprises a coating that 14 provides a barrier for nuclear, biological and chemical hazards. 16 17 Most preferably the oxygen mask provides an air tight 18 seal about the user's nose and mouth. 19

Optionally the flexible cowl further comprises a 21 detachable front face connected to the flexible cowl by a 22 first airtight seal. 23 24 Preferably the first airtight seal comprises a beading edge associated with the detachable front face, a channel 26 associated with the flexible cowl and suitable for 27 receiving the beading edge and a zip mechanism suitable 28 for opening and sealing the first airtight seal. 29

Optionally the flexible cowl comprises attachment point 31 access holes and compression seals. 32 33 Optionally the flexible cowi further comprises a head 34 cowl and a detachable lower section wherein the head cowl

1 and detachable lower section are connected by a second 2 airtight seal. 3 4 Preferably the second airtight seal comprises a beading . 5 edge associated with the head cowl, a channel associated 6 with the detachable lower section and suitable for 7 receiving the beading edge and a zip mechanism suitable 8 for opening and sealing the second airtight seal. 9

Preferably the first rigid helmet further comprises an 11 energy absorbing liner, attachment points suitable for 12 threading through the attachment point access holes such 13 that the first rigid helmet can be connected to the 14 second rigid helmet. 16 Preferably the first rigid helmet further comprises ear 17 phones and at least one earphone aperture associated with 18 each earphone. 19

Preferably the first rigid helmet further comprises 21 attachment means suitable for connecting oxygen mask 22 mounting means of the oxygen mask to the first rigid 23 helmet. 24

Optionally the first rigid helmet comprises a retractable 26 earphone mount wherein the retractable earphone mount 27 comprises & bias means that acts to maintain an 28 associated earphone in a first position and a retracting 29 means suitable for overcoming the bias means such that the associated earphone is moved to a second retracted 31 position suiteble for aiding the donning and dofiing of 32 the integrated respirator.

1 Preferably the retracting means comprises a draw string 2 threaded through an aperture in the first rigid helmet. 3 Optionally the first rigid helmet further comprises a 4 securing means to which the draw string can be attached . 5 so as to maintain the retractable earphone mount in the 6 second retracted position. 7 8 Most preferably the first visor locates within the first . 9 visor aperture so providing a visor airtight seal with the flexible cowl. 11 12 Optionally the visor airtight seal provides means for 13 adjustment of the position of the first visor relative to 14 the rigid helmet. 16 Preferably the means for adjustment allows the visor to 17 move to a displaced position suitable for aiding the 18 donning and doffing of the integrated respirator. 19

Optionally the second rigid helmet further comprises a 21 second visor. 22 23 Preferably the first and second visors comprise a high 24 optical quality material that provides a barrier for nuclear, biological and chemical hazards. 26 27 According to a second aspect of the present invention 28 there is provided a method of fabricating an integrated 29 respirator in accordance with the first aspect of the present invention comprising: 31 1) Fabricating a flexible cowl; 32 2) Forming an oxygen mask location area and a 33 viscr aperture in the flexible cowl;

1 3) Locating a visor within the visor aperture so 2 as to form an airtight seal between the visor 3 and the flexible cowl; 4 4) Locating an oxygen mask within the oxygen mask suspension system aperture so as to form an 6 airtight seal between the oxygen mask and the 7 flexible cowl; and 8 5) Attaching the flexible cowl to a first rigid 9 helmet so as to form an airtight seal between the first rigid helmet and the flexible cowl. 11 12 Preferably location points on the helmet ensure that the 13 flexible cowl is correctly located on the first rigid 14 helmet and provide means for connecting the first rigid helmet to a second rigid helmet. 16 17 Most preferably the flexible cowl is fabricated by: 18 1) Vacuum forming a flexible material and fixing the 19 vacuum formed material by seam welding; 2) Fabricating an airtight neck seal and attaching 21 said neck seal to the vacuum formed material; 22 23 preferably the step of fabricating the flexible cowl 24 further comprises the steps of: 1) Connecting a visor mist air supply to the wvacuum 26 formed material; and 27 2) Connecting a pressure release valve to the vacuum 28 formed material. 29

Preferably the visor is injection moulded from a material 31 of high optical coating. Thereafter the outer surface of 32 the visor is coated with a nuclear, biological and 33 chemical resistant coating. Optionally the inner surface 34 of the visor is coated with an anti fogging coating.

2 Embodiments of the invention will now be described, by 3 way of example only, with reference to the accompanying 4 drawings, in which: : 5 6 Figure 1 present a schematic representation of an 7 integrated respirator in the absence of an 8 outer helmet in accordance with an aspect of 9 the present invention;

Figure 2 present a schematic representation of the outer 11 helmet suitable for use with the integrated 12 respirator of Figure 1; 13 Figure 3 presents detail of an inner helmet of the 14 integrated respirator of Figure 1;

Figure 4 presents detail of an oxygen mask of the 16 integrated respirator of Figure 1; 17 Figure 5 presents detail of a flexible cowl of the 18 integrated respirator of Figure 1; 19 Figure 6 presents detail of a connection means for a visor and the flexible cowl of Figure 5: 21 (a) when the visor is positioned over a user's 22 eyes; and 23 (b) when the visor is in a displaced position 24 suitable for donning and doffing the integrated respirator; 26 Figure 7 presents detail of an alternative embodiment 27 connection means for the visor and the flexible 28 cowl of Figure 5; 29 Figure 8 illustrates the formation of the integrated respirator by employing a vacuum forming 31 method; 32 Figure 9 presents an alternative embodiment of the 33 integrated respirator in accordance with 34 aspects of the present invention;

I Figure 10 presents detail of an attachment means of the 2 integrated respirator of Figure 9; 3 Figure 11 presents a further alternative embodiment of 4 the integrated respirator in accordance with : 5 aspects of the present invention; and 6 Figure 12 presents a yet further alternative embodiment 7 of the integrated respirator in accordance with 8 aspects of the present invention; 9 Figure 13 presents detail of a connection means for an 10 earphone and a flexible cowl of the integrated 11 respirators of Figure 11 and 12: 12 (a) when the earphone is positioned over a 13 user's ear; and 14 (b) when the earphone is in a displaced position suitable for donning and doffing 16 the integrated respirator. 17 Figure 14 presents an alternative embodiment for the 18 incorporation of the oxygen mask and the 19 flexible cowl.

21 Figure 1 presents an integrated respirator 1 in 22 accordance with an aspect of the present invention.

The 23 integrated respirator 1 can be seen to comprise an inner 24 helmet 2, an oxygen mask suspension system 3, a visor demist air supply 4, a flexible cowl 5 on which is 26 mounted a first visor 6 and a non-return exhaust valve 7. 27 28 The first visor 6 shown in Figure 1 is manufactured from 29 a high optical guality material and is bonded or welded to the flexible cowl 5. NBC hazards when deposited on 31 the visor would attack the surface of conventional 32 polycarbonate visors therefore, to protect the visor a 33 NBC resistant coating is applied to the outer surface.

1 The inner surface is also be coated with an anti fogging 2 coating. 3 4 The visor demist alr supply 4 also helps to prevent the : 5 misting of the visor by supplying a flow of air that is 6 directed over the visor.

The air, in normal mode, is 7 exhausted from the flexible cowl 5 through the non-return 8 exhaust valve 7 such that a positive pressure is 9 maintained within the cowl.

11 Figure 2 presents an outer helmet 8 suitable for use with 12 the integrated respirator 1. The outer helmet 8 13 comprises an outer shell 9 on which are located outer to 14 inner helmet attachment points 10 and a detachable second visor 11. 16 17 Details of the inner helmet 2, the oxygen mask 3 and the 18 flexible cowl 5 are presented in Figures 3, 4 and 5 19 respectively.

The inner helmet 2 comprises an NBC resistant shell 12 with attachment points 13 for both the 21 outer helmet 8 and oxygen mask suspension system 3. The 22 inner helmet 2 is lined with impact absorbing liners 14 23 and earphones 15 and earphone cabling 16 are attached to 24 the inner surface.

26 The oxygen mask suspension system 3, shown in Figure 4 27 comprises a face seal 17 that acts to isolate the mask 28 oro-nasal breathing cavity from the flexible cowl 5 and 29 the first wviscr 6. Therefore, tne face seal 17 helps prevent misting of the first visor 6 by exhaled gases 31 from the user.

Breathing gas is supplied to the user by 32 inhalation through a non-return inspiratory valve 18. On being exhaled the gas exits the oxygen mask suspension 34 system 3 through a first non-return expiratory valve 19.

1 To prevent any reverse gas flow into the oxygen mask 2 suspension system 3 a second non-return valve 20 is 3 fitted in series with the first 19 so as to create an 4 isclating chamber 21. : 5 6 An examination of Figure 4 shows that the oxygen mask 7 suspension system 3 further comprises two mask mounting 8 means 22, two mask retention assemblies 23 and a gas 9 supply hose 24. The combination of the mask mounting means 22 and the mask retention assemblies 23 allow the 11 oxygen mask suspension system 3 to be directly connected 12 to the inner helmet therefore helping to maintain the air 13 tight seal between the face seal 17 and the flexible cowl 14 5S.

16 The gas supply hose 24 comprises a flexible pipe that is 17 resistant to penetration by NBC contaminants.

The hose 18 24 is connected at one end to the face seal 17 while the 19 other end is coupled to a supply of filtered air or oxygen from an aircraft oxygen generator.

The gas supply 21 hose 24 can also be coupled to a portable air supply for 22 transit to and from an aircraft. 23 24 The flexible cowl 5 shown in Figure 5 specifically covers the portion of the head and neck of the user that is not 26 protected by the inner helmet 2 and any NBC clothing worn 27 by the user.

A neck seal 25 provides the required 28 airtight seal between the flexible cowl and the user's 29 neck.

31 The oxygen mask suspension system 3 and the first visor © 32 are attached to the flexible cowl 5 and sealed to form a 33 leak proof assembly.

The non-return exhaust valve 7 acts 34 as a pressure relief valve to prevent over pressurisation

1 within the flexible cowl 5. The non-return exhaust valve 2 7 itself comprises non-return valves in series so as to

3 prevent any reverse flow of gases back into the flexible 4 cowl 5.

: 5 6 When the integrated respirator 1 is correctly mounted on 7 the head, the oxygen mask suspension system 3 determines 8 the viewing aperture located between the oxygen mask 3 9 and the brow of the inner helmet 2. This viewing aperture, and in particular the vertical distance, varies 11 from subject to subject.

Therefore, to accommodate these 12 wvarietions, with a minimum number of visor sizes, an 13 adjustable means 26 of fitting the first visor 6 to the 14 flexible cowl has been developed.

16 Figure 6(a) presents detail of the adjustable means 26 17 that is characterised in that it is larger in the 18 vertical dimension, than the viewing aperture provided. 19 A space under the brow of the inner helmet 2 is produced by foreshortening the energy absorbing liner 14. 21 Therefore, when the first visor 6 1s too large for the 22 aperture the top of the first visor 6 is inserted into 23 the space underneath the inner helmet 2 as shown.

The 24 upper area of the flexible cowl 5 has sufficient material to allow the first visor 6 to move into the space 26 underneath the inner helmet 2. Similarly sufficient 27 material is provided between the oxygen mask suspension 28 system and the first visor 6 so as to set the distance

29 between the eyes and the inner surface of the first visor 6. To hold the first visor 6 in the optimum position it 31 can be attached directly to the inner helmet 2 by, for 32 example, draw strings or retaining clips that engage with 33 receivers on the helmet.

1 A further advantage of incorporating the visor adjustment 2 means 26 within the integrated respirator 1 can be seen 3 in Figure 6(b). When donning the integrated respirator 1 4 the excess material of the flexible cowl 5 around the first visor 6 and the oxygen mask suspension system 3 6 permits both of these elements to be displaced to a 7 position suitable for aiding the donning and doffing of 8 the integrated respirator 1. 9

An alternative adjustment means 27 that also provides a 11 method of accommodating the variations in vertical height 12 between the oxygen mask suspension system 3 and the inner 13 helmet 2 1s shown in Figure 7. In this case, the 14 flexible cowl material that attaches the first visor 6 to the brow and side apertures of the inner helmet 2, allows 16 for fore and aft adjustment. As such the lower portion 17 of the first visor 6 can sit over the oxygen mask 18 suspension system 3. 19

To assemble the integrated respirator 1, the flexible 21 cowl 5, with integral visor 6 and oxygen mask suspension 22 system 3, is pulled over the inner helmet 2. Location 23 points can be provided on the inner helmet 2 to ensure 24 that the flexible cowl 5 is correctly positioned. This ensures the respirator components, such as the visor 6 26 and oxygen mask suspension system 3, are correctly 27 positioned. The overlap area between the inner helmet 2 28 and the flexible cowl 5 is bonded to ensure a leak tight 29 seal preventing any ingress of agents when there is a negative pressure inside the visor 6 or inner helmet 2. 31 32 The Zflexible cowi 5 and inner helmet 2 assembly when 33 donned, is not in contact with the user's head but 34 contacts the user at the neck seal 25 area. This

1 configuration prevents unacceptable levels of discomfort 2 when wearing the NBC head protection. 3 4 By employing the aforementioned adjustment means, 26 or 27, provides that one particular flexible cowl 5 can be 6 used in conjunction with a number of inner helmets 2 of 7 varying dimensions. This factor increases the 8 compatibility of employing the same design of integrated 9 respirator 1 with different users while allowing minor adjustments to increase user comfort. 11 12 Additional protection for the flexible cowl from 13 penetration by debris during and after ejection from an 14 aircraft may also be achieved by incorporating a hood (not shown) that is attached tc the lower edge of the 16 inner helmet so as to envelope the flexible cowl. Such a 17 hood provides further fire proof, snag proof and 18 windblast proof properties to the integrated respirator. 19

One method of fabricating the integrated respirator 1 is 21 to vacuum form the developed shape of the flexible cowl 5 22 from a sheet of NBC resistant flexible material as shown 23 in Figure 8. The flexible cowl 5 is formed by seam 24 welding to produce a leak-tight joint 28. Thereafter, the oxygen mask suspension system 29 and visor apertures 26 30 are cut out of the flexible cowl. 27 28 The visor 6 is then injection moulded, for example from 29 polycarbonate to a high optical quality and coated with a

NBC resistant coating on the outside surface and with an 31 anti fogging coating, if required, on the inside. 32 Bonding areas of the visor 6 and the flexible cowl 5 are 33 then prepared and the visor coating can, if required, be 34 stripped off to provide a suitable bonding surface. The

1 visor 6 can then be bonded to the flexible cowl 5 using a 2 suitable adhesive. 3 4 In a similar manner the oxygen mask suspension assembly 3 : 5 is located within the appropriate aperture 29 and bonded 6 with the flexible cowl 5 so as to produce the required 7 leak tight seal.

This may be achieved by the flexible § cowl 5 being either fitted over or under the oxygen mask 9 suspension assembly 3.

11 The neck seal 25 is also formed from a flexible NBC 12 resistant material and bonded to the flexible cowl 5 to 13 provide the required leak-tight seal at the neck area of 14 the user.

16 An alternative embodiment of the integrated respirator 1 17 is shown in Figure 9. In this embodiment the flexible 18 cowl 5 comprises a detachable front section 31. Located 19 on the front section 31 are the first visor 6 and the oxygen mask suspension system 3. Therefore, the 21 detachable front section 31 allows for the removal of the 22 first visor 6 and oxygen mask suspension assembly 3 if 23 access is required in, for example, an emergency where 24 the inspiratory 18 or expiratory valves 19 and 20 have jammed or the demist air supply 4 has failed. 26 27 The detachable front section 31 is attached and detached 28 by means of an airtight seal 32, detail of which are 29 provided in Figure 10. The airtight seal 32 comprises a beaded edge 33 formed on the front section 31 and a 31 channel 34 that matches the shape of the beading 33, 32 formed or the flexible cowl 5. A zip 35 operating in zip 33 guides 36 formed in the flexible cowl 5 and the front 34 section 31 pull the front section beaded edge 33 into the

1 channel 34 in the flexible cowl 5 thus forming a leak 2 proof seal, as required. 3 4 A further alternative embodiment of the integrated : 5 respirator is shown in Figure 11. Here the flexible cowl 6 5 is formed by vacuum forming and fabricating a hood from 7 a material that will stretch sufficiently to allow the 8 neck seal 25 to pass over the inner helmet 2. The oxygen 9 mask suspension system 3 and the first visor 6 are then fitted as described above. 11 12 Access to the inner to outer helmet fixing points 13 is 13 achieved by means of apertures 37 provided in the 14 flexible cowl 5. Sealing of the flexible cowl 5 to the inner helmet 2 can be achieved by means of compression 16 seals 38. The compression seals 38, attached to the 17 flexible cowl 5, are compressed against the inner helmet 18 2 when the outer helmet 8 is placed on the user's head by 19 the presence of the outer to inner helmet attachment points 10. 21 22 A yet further alternative embodiment of the integrated 23 respirator is shown in Figure 12. In this particular 24 embodiment the flexible cowl 5 consists of two parts.

The first part comprises a head cowl 39 that fits over 26 the inner helmet 2 while the second comprises a 27 detachable lower portion 40 that protects the neck and 28 shoulder area. The lower portion 40 can be formed from a 29 flexible material that provides increased mobility for the user. The two parts are held together by a leak 31 proof joint 41 that is similar to that described in 32 Figure 10. The head cowl 39 can be manufactured to 33 conform to the shape of the inner helmet 2. As the lower 34 portion contains the neck seal 25, this 1s the only

1 component that is required to stretch over the head 2 during fitting. ) 3 4 The integrated respirators shown in Figures 11 and 12 may ‘ 5 be further adapted, so as to incorporate retractable 6 earphones 42 as presented in Figure 13. Each earphone 15 7 is mounted on the flexible respirator by means of 8 Velcro ® A leaf spring 43 mounted on the inner surface 9 of the inner helmet 2, biases the earphone 15 (or foam padding) in a first position as shown in Figure 13(a). 11 When a user pulls on a draw string 44, attached to the 12 leaf spring 43, the bias force is overcome and the 13 earphone 15 (or foam padding) is moved to a second, 14 retracted position, as shown in Figure 13{(b). The earphone 15 can be fixed in the retracted position by 16 securing the draw string to a an attachment means (not 17 shown). The attachment means can be in the form of 18 Velcro ®, a stud fastener, a hook or any other suitable 19 means.

On releasing the draw string 44 from the attachment means the bias force of the leaf spring 43 21 acts to return the earphone 15 back to the first 22 position.

A compressible foam liner (not shown) may also 23 be located between the leaf spring 43 and the inner 24 helmet 2 so as to aid in the positioning of the earphone 15. 26 27 The retractable earphones 42 provide a means for allowing 28 the earphones 15 to be easily displaced thus aiding the 29 donning and doffing of the integrated respirator.

This is particularly advantageous for user's who require the 31 use of spectacles as the retractable earphones 42 allow 32 the integrated respirator to be employed without 33 dislodging the spectacles from the user.

1 In a further embodiment, shown in Figure 14, an 2 alternative design for the incorporation of the oxygen . 3 mask 3 and the flexible cowl 5 is presented. In this 4 embodiment the flexible cowl 5 generally envelopes the : 5 oxygen mask 3. The required sealing of the oxygen mask 6 is achieved by clamping the various components of the 7 oxygen mask to the face seal 17 via a number of apertures § created in the flexible cowl 5 e.g. an inspiratory valve 9 aperture 45, an expiratory valve 46 aperture, a communication cables aperture 47 and a drinking tube 48 11 aperture. The number of apertures created in the 12 flexible «cowl will obviously be dependent on the 13 particular design of the oxygen mask to be employed. 14

The integrated respirator described in aspects of the 16 present invention exhibits several key advantages over 17 those described in the Prior Art. 18 19 When deployed by a user the integrated respirator provides a significantly high level of comfort and user 21 acceptability since it 1s designed to avoid direct 22 contact with the user’s head. The integrated respirators 23 thereby provide space for head cooling while 24 simultaneously help to eliminate the feeling of claustrophobia and stress that are known to result from 26 respirator hoods that fit closely over the wearer’s head. 27 Further embodiments of the present invention incorporate 28 an adjustable visor and retractable earphones both being 29 features that aid in the donning and doffing of the respirator. 31 32 The integrated respirator designs describe above 33 inccrporate a certain degree of inherent flexibility. 34 This flexibility allows the integrated respirators to be

1 adjusted so as to improve user comfort while also 2 permitting the same design to be employed by different } 3 users.

In addition the present design reduces any 4 alignment problems experienced by designs discussed in : 5 the Prior Art. 6 7 A further advantage of the integrated respirators 8 described herein is that they can be simply manufactured. 9 This manufacturing process is flexible and so enables the use of the most appropriate materials for NBC protection, 11 user acceptability and ease of manufacture. 12 13 The foregoing description of the invention has been 14 presented for purposes of illustration and description and is not intended to be exhaustive or to limit the 16 invention to the precise form disclosed.

The described 17 embodiments were chosen and described in order to best 18 explain the principles of the invention and its practical 19 application to thereby enable others skilled in the art to best utilise the invention in various embodiments and 21 with various modifications as are suited to the 22 particular use contemplated.

Therefore, further 23 modifications or improvements may be incorporated without 24 departing from the scope of the invention herein intended.

Claims (1)

1 Claims

3 1) An integrated respirator that provides an airtight 4 barrier for a user's head comprising a first rigid helmet and a flexible cowl having an airtight neck 6 seal, wherein the first rigid helmet defines an 7 access aperture suitable for locating directly on a 8 user's head and the flexible cowl is sealably fixed 9 to the first rigid helmet so providing a physical barrier for the access aperture while forming an 11 airtight seal with a user's neck. 12 13 2) An integrated respirator as claimed in Claim 1 14 wherein the first rigid helmet and the flexible cowl comprise a material that protects against nuclear, 16 chemical and biological hazards. 17 1§ 3) An integrated respirator as claimed in Claim 1 or 19 Claim 2 wherein the flexible cowl completely encloses the first rigid helmet. 21 22 4) An integrated respirator as claimed in Claim 1 or 23 Claim 2 wherein the flexible cowl is connected to the 24 periphery of the access aperture.

26 5) An integrated respirator as claimed in Claim 1 or 27 Claim 2 wherein the flexible cowl ccnnects to an 28 inner surface of the first rigid helmet. 29 6) An integrated respirator as claimed in any of the 31 preceding claims wherein the first rigid helmet 32 provides a tight fit with the user's head.

Zz

7) An Integrated respirator as claimed in any of the crececing claims wherein tre integrated respirator furtrer comprises a hood that is fixed to the fire: rigid helmet so providing a physical barrier for the flexible cowl thus improving the fire proof, snag proof znd windblast proof properties of the integrated respirator. 8) An integrated respirator as claimed in any of the preceding claims wherein the flexible cowl comprises a visor aperture, an oxygen mask location area, a visor mist air supply and a pressure release valve.

9) An integrated respirator as claimed in any of the preceding claims wherein the integrated respirator

ZZ further comprises a second rigid helmet suitable for locating over the first rigid helmet.

10) An integrated respirator as claimed in any of the preceding claims wherein the integrated respirator further comprises an oxygen mask and a first visor.

11; An integrated respirator as claimed in Claim 8 wherein the oxygen mask location area comprises a plurality of apertures suitable for receiving one or more component

Z5 parts of the oxygen mask when the oxygen mask is located within the oxygen mask location area.

12) En integrated respirator as claimed in Claim 8 wherein the oxygen mask location area comprises a single aperture

20 suitable for receiving the oxygen mask.

[ Ar integrated respirator as claimed in ary cone of Claims 175

5 12 wherein the oxygen mesk comprises a coating that AMENDED SHEET DATED 30 MAY 2006 provices a Zoarrier for nuclear, biological and chemical hazards.

14 An integrated respirator as claimed in any one of Claims 0 z to 13 the oxygen mask provides arn air tight seal about the user's nose and mouth. 15; An . integrated respirator as claimed in any of the preceding claims wherein the flexible cowl further

20 comprises a detachable front face connected +o the flexible cowl by a first airtight seal.

16) An integrated respirator as claimed in Claim 15 wherein the first airtight seal comprises a beading edge associated with the detachable front face, a channel associated with the flexible cowl and suitable for receiving the beading edge and a zip mechanism suitable for opening and sealing the first airtight seal.

17) An 1ntegrated respirator as claimed in any of the preceding claims wherein the flexible cowl comprises attachment point access holes and compression seals.

18) An integrated respirator as claimed in any of the preceding claims wherein the flexible cowl further comprises a head cowl and a detachable lower section the head cowl and detachable lower section being connected by a second airtight seal.

3 19) En integrated respirator as, claimed in Claim 17 wherein -he second airtight seal comprises a beading edoe zssociz-ed with the head cowl, az channel associated with -he detachable lower section and suitanles for receiving

AMENDED SHEET DATED 30 MAY 2006 the Zz2z2ding edge and a zip mechanism sultanis for ocening and sealing The second alriticgnT sez.

20) An Integrated respirator as claimed in any one oi

Z Claims 17 to 19 wherein the ZIirst rigid helmet further comprises an energy absorbing liner, attachment points suitable for threading through the attachment point access holes such that the first rigid helmet can be connected to the second

20 rigid helmet.

21; An Integrated respirator as claimed in any of the preceding claims wherein the first rigid helmet further comprises ear phones and at least one earphone aperture associated with each earphone.

22) An Integrated respirator as claimed in any one of Claims 10 to 21 wherein the first rigid helmet further comprises attachment means suitable for connecting oxygen mask mounting means of the oxygen mask to the first rigid helmet.

23) An integrated respirator as claimed in Claim 21 or Claim 22 wherein the first rigid helmet comprises a retractable earphone mount wherein the retractable earphone mount comprises a bias means that acts to maintain an associated earphone in a first position and a retracting means suitable for overcoming the bilas means such that the associated earphore is moved to & second retracted position suitable for aiding the. donning and decffing of the integrated respirator.

AMENDED SHEET DATED 30 MAY 2006

WG 2054/055142 cIT/GRBZ0TE/00452C

24) An integrated respirator 2s c_aimed In Claim 22 wherein the retrac:ilng means Comprises 2 draw string threaded tnrough an aperture in the first rizic helmet.

25) An integrated respirator as claimed in Claim 24 wherein the first rigid helmet further comprises a securing means to which the draw string can be attached so as to maintain the retractable earphone mount in the second retracted position.

26; An Integrated respirator as claimed In any one of Claims 10 to 22 wherein the first visor locates within The first visor aperture so providing a visor alrtight seal with the flexible cowl.

27) An integrated respirator as claimed in Claim 26 wherein the visor airtight seal provides means for adjusting the position of the first visor relative to

26 the first rigid helmet.

28) An integrated respirator as claimed in Claim 27 wherein the means for adjustment allows the visor to move to a displaced position suitable for aiding the donning and doffing of the integrated respirator.

29) An integrated respirator as claimed in any one of Claims 9 to 28 wherein the second rigid helmet: further comprises a second visor.

3C) En integratéd respirator as claimed in Claim 29 wherein the first and second visors comprise a high CoTica. cua_ity material that provides 2 harrier for ruclear, nDiclogical and chemical razaracs.

AMENDED SHEET DATED 30 MAY 2006

1 31) A method of fabricating an integrated respirator

2 comprising the steps cf:

3 1) Fabricating a flexible cowl; 4 2) Forming an oxygen mask location area and a visor aperture in the flexible cowl;

6 3) Locating a visor within the visor aperture so

7 as to form an airtight seal between the visor

8 and the flexible cowl;

9 4) Locating an oxygen mask within the oxygen mask suspension system aperture so as to form 11 an airtight seal between the oxygen mask and 12 the flexible cowl; and 13 5) Attaching the flexible cowl to a first rigid 14 helmet so as to form an airtight seal between the first rigid helmet and the flexible cowl. 16 17 32) A method of fabricating an integrated respirator as 18 claimed in Claim 31 wherein location points on the 19 helmet ensure that the flexible cowl is correctly located on the first rigid helmet and provide means 21 for connecting the first rigid helmet to a second 22 rigid helmet.

23

24 33) A method of fabricating an integrated respirator as claimed in Claim 31 or Claim 32 wherein the step of

26 fabricating the flexible cowl further comprises the

27 steps of:

28 1) Vacuum forming a flexible material and fixing

29 the vacuum formed material by seam welding;and

2) Fabricating an airtight neck seal and attaching 31 said neck seal to the vacuum formed material;

34 A metrod oI fapricating an integrated respirator as claimed in Claim 33 wherein the step of fabricating tre flexible cowl further comprises the steps of: 1) Connectirg a visor mist air supply to the vacuum formed material; and 2) Connecting a pressure release valve to +*he vacuum formed material.

35) A method of fabricating an integrated respirator as claimed in any one of Claims 31 to 34 wherein the step of locating the visor further comprises the step of injection moulding the visor from a material of high optical coating.

36) A method of fabricating an integrated respirator as claimed in any one of Claims 31 to 35 wherein -he step of locating the visor further comprises the step of coating the outer surface of the visor with a nuclear, biological and chemical resistant coating.

37) A method of fabricating an integrated respirator as claimed in any one of Claims 31 to 36 wherein the step of locating the visor further comprises the steps of coating the inner surface of the visor with an anti-fogging coating.

: AMENDED SHEET DATED 30 MAY 2006