Gas sensing drift compensation using gas self-referencing for end of service life indication for respirators

• US 9,283,411 B2
• Filed: 04/19/2013
• Issued: 03/15/2016
• Est. Priority Date: 04/19/2013
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Larsen, Christopher Scott, Tobias, Peter, McIntosh, Andrew
• Primary Examiner(s): Martin, Laura
• Assistant Examiner(s): Devito, Alex
• Application Number:
  US13/866,770
• Publication Number:
  US 20140311211A1
• Time in Patent Office: 1,061 Days
• US Class Current: 1/1
• CPC Class Codes: A62B 18/088 Devices for indicating filter saturation
• CPC Class Codes: A62B 9/006 Indicators or warning devices, e.g. of low pressure, contamination

Abstract

Embodiments relate generally to systems and methods for determining end of service life for a respirator cartridge by comparing the gas levels sensed at two or more sample points within the cartridge. Sample streams may run from the sample points to a gas sensor, wherein a valve may control the flow between the sample streams and the gas sensor.

Claims

1. An end-of-service-life indicator system for a filter cartridge for a respirator, comprising:

a gas sensor;

at least two sample streams from the cartridge alternatively in fluid communication with the gas sensor; and

a valve controlling the flow from the at least two sample streams to the gas sensor, wherein the gas sensor compares the at least two sample streams;

wherein each of the least two sample streams samples from sample points within the cartridge and the sample points for the sample streams are located at different depths within the cartridge.

2. The system of claim 1, further comprising an alert coupled to the gas sensor operable to indicate approaching end-of-service-life of the cartridge, wherein approaching end-of-service-life is indicated when a gas level sensed at a sample point proximate to a rearward end of the cartridge approaches a gas level sensed at a sample point proximate to a forward end of the cartridge.

3. The system of claim 1 wherein the gas sensor comprises one of a metal-oxide sensor or an electrochemical sensor.

4. The system of claim 1 wherein the valve comprises one or more of the following:

a piezoelectric valve, a solenoid valve, a bi-stable solenoid valve, a flap valve actuated by the pressure from a user'"'"'s breathing, a check valve, a valve actuated by user motion, and an electrostatic valve.

5. The system of claim 1 wherein the valve comprises a mechanical valve comprising an indexing mechanism, a diaphragm that activates the indexing mechanism, and a line to the interior of the respirator, wherein the valve is actuated by the pressure from a user'"'"'s breathing within the respirator.

6. The system of claim 1 wherein the valve is actuated by the pressure from a user'"'"'s breathing and switches the flow to the gas sensor from one of the at least two sample streams to another of the at least two sample streams after a set number of breathing cycles.

7. The system of claim 1 wherein the valve comprises a two-way valve operable to alternate between one sample stream and a mixture of the at least two sample streams.

8. The system of claim 1 Wherein the valve comprises a three-way valve operable to alternate between a first sample stream and a second sample stream.

9. The system of claim 1 wherein the at least two sample streams comprise three or more sample streams from three or more different sample points within the cartridge, wherein the gas sensor compares the sample streams from the three or more sample points.

10. The system of claim 9 further comprising an alert in communication with the gas sensor, wherein the alert comprises a plurality of indications or warnings to indicate to the user when the gas has penetrated to each of the three or more different sample points in the cartridge.

11. An end-of-service-life indicator system for a filter cartridge for a respirator wherein the cartridge has a forward end and a rearward end, comprising:

a gas sensor;

sample streams from at least two sample points in the cartridge to the gas sensor, wherein the gas sensor compares the gas level of the two sample streams, and wherein one sample point is proximate to the rearward end of the cartridge and another sample point is proximate to the forward end of the cartridge; and

a valve controlling the flow from the at least two sample streams to the gas sensor, wherein the valve comprises;

an air tight housing with an opening in fluid communication with the interior of a mask of the respirator and the breathing of a user, and a plurality of ports in fluid communication with the gas sensor and the sample streams,

a diaphragm operable to move in response to pressure changes caused by the breathing of the user within the respirator,

two or more seals operable to isolate a portion of the housing about one or more of the plurality of ports, wherein the seals are operable to control flow through the plurality of ports from the sample streams to the gas sensor, and

an indexing mechanism coupled to the diaphragm and to the seals, such that movement of the diaphragm activates the indexing mechanism, thereby positioning the seals with respect to the plurality of ports and controlling flowfrom the sample streams to the gas sensor.

12. The system of claim 11 wherein the seals of the valve allow one sample stream to reach the gas sensor at a time depending on the position of the indexing mechanism.

13. The system of claim 11 wherein the indexing mechanism positions the seals to alternate the sample streams at a multiple of breathing cycles of a user, to ensure that the

breathing cycle can always be used to drive flow in a single direction to the gas sensor.

14. The system of claim 11 wherein the diaphragm of the valve comprises over-molded rubber and is fixed to an inner wall surface of the housing.

15. The system of claim 11 wherein approaching end-of-service-life is indicated when the gas level sensed at the sample point proximate to the rearward end of the cartridge approaches the gas level sensed at the sample point proximate to the forward end of the cartridge.

16. The system of claim 11 wherein comparing the at least two sample streams overcomes the effect of voltage drift on the accuracy of the gas sensor.

17. A method of detecting effective-end-of-service-life for a filter cartridge for a respirator using a gas sensor for detecting gas levels comprising:

receiving sample streams from at least two sample points in a filter cartridge, wherein the two or more sample points are located at different depths within the cartridge;

alternating the flow from the sample streams to the gas sensor via a valve; and

comparing the gas level present in the sample streams.

18. The method of claim 17 further comprising indicating end of service life when the two sample streams approach equality for a second time, wherein initially the sample streams are approximately equal because no gas has penetrated the cartridge, then the sample streams become unequal as gas penetrates to a forward sample point, and then the sample streams approach equality once again as gas penetrates further in the cartridge to the rearward sample point.

19. The method of claim 17 wherein a gas sensor receives the at least two sample streams and compares the gas level present in the at least two sample streams.

20. The method of claim 17 wherein the valve comprises one or more of the following:

a piezoelectric valve, a solenoid valve, a bi-stable solenoid valve, a flap valve or mechanical valve actuated by the pressure from a user'"'"'s breathing, a check valve, a valve actuated by user motion, and an electrostatic valve.