Smart Respirators - Embedded detectors for real-time monitoring of end-of-service-life in respirator filter cartridges

项目摘要/摘要：石油和天然气等许多行业的工人都戴着口罩， 金属加工、危险材料、化学研究和制造。普通有机蒸气(OV) 口罩使用可定期更换的滤嘴或滤芯，价格从5美元到40美元不等，具体取决于 保护级别和制造商。可更换过滤器的使用寿命变化很大，这取决于 佩戴者的肺活量、化学物质暴露的类型和浓度以及环境因素，并可能范围 从几分钟到几天。目前还没有明确的方法来识别即将发生的保护故障 而且，也没有“智能”滤芯能够可靠地提醒佩戴者即将取得突破。 在这项SBIR中，海岸科学公司正在开发可嵌入的探测器，以创造新的“智能呼吸器”， 根据霍尼韦尔安全产品公司提供的规范，检测 滤芯上方。霍尼韦尔正在开发一种无线接口，它将与传感器和 在化学突破前向用户提供警告。这些实时探测器将测量 与各种高危职业相关的化学蒸气浓度。这是第一步 为各种化工行业的工人制造智能个人防护设备。最终， 来自智能墨盒的数据可以无线链接到曝光/位置映射系统，以帮助识别 操作故障，如化学品泄漏，因此工作场所可以变得更安全。 在第一阶段，海岸公司确定了适用于各种电容和阻抗的化学敏感材料- 基于传感器的丙酮、甲苯和三氯乙烯的高灵敏度检测。原型被嵌入到 不同位置的过滤器，在NIOSH过滤器使用寿命测试中指定的各种条件下进行测试 程序，并成功地用于实时跟踪过滤器的内部浓度。丙酮检测器 满足霍尼韦尔在尺寸、功率、重量、灵敏度和基准特性方面的所有要求。我们也 研究了用于改善甲苯和三氯乙烯检测的聚合物-纳米复合材料。一 纳米复合材料成功地实时跟踪了过滤器内的这两种化学物质，并证明了它 可以进行扩展以满足霍尼韦尔的需求。这些传感器仍然需要对灵敏度和功率进行优化。 第二阶段将专注于准备化学敏感材料和换能器，以便通过销售 或授权给过滤器制造商。第二阶段的具体目标是：(1)优化和完成 丙酮、甲苯和三氯乙烯探测器；(2)将工作样机交付霍尼韦尔进行验证测试 他们的过滤器测试实验室；(3)支持霍尼韦尔的无线读出电路和传感器集成开发；以及(4) 制定支持商业化的制造和过渡计划。霍尼韦尔测试了海滨 原型和我们的第一阶段成果与他们的团队共享。霍尼韦尔迫切希望支持我们的第二阶段到 为美国化工制造业的544,000多名工人制造智能呼吸器。

Project Summary/Abstract: Respirator masks are worn by workers in many industries, such as oil and gas, metal working, hazardous materials, and chemical research and manufacturing. Common organic vapor (OV) respirator masks employ periodically replaceable filter cannisters or cartridges, costing $5 to $40, depending on level of protection and manufacturer. The service life of a replaceable filter is highly variable, depending on the wearer's lung capacity, type and concentration of chemical exposure, and environmental factors, and may range from minutes to days. Currently there is no definitive means to recognize impending break-down in protection and there are no “smart” filter cartridges capable of reliably alerting the wearer to imminent breakthrough. In this SBIR, Seacoast Science, Inc. is developing embeddable detectors to create new “Smart Respirators”, guided by specifications provided by Honeywell Safety Products, Inc., to detect the end of service life (EOSL) in OV filter cartridges. Honeywell is developing a wireless interface which will interface with the sensors and provide the user with a warning before chemical breakthrough. These real-time detectors will measure concentrations of chemical vapors associated with a wide range of high-risk occupations. This is the first step to creating smart personal-protective equipment for workers in a wide range of chemical industries. Ultimately, data from smart cartridges can be wirelessly linked to an exposure/location mapping system, to help identify operational failures such as chemical leaks, so the workplace can be made safer. In Phase I, Seacoast identified chemosensitive materials applied to various capacitance- and impedance- based transducers for high-sensitivity detection of acetone, toluene and TCE. Prototypes were embedded in filters in different locations, tested in a variety of conditions as specified in the NIOSH Filter Service Life test procedure, and successfully used for real-time tracking of the filter's internal concentration. The acetone detector met all of Honeywell's requirements for size, power, weight, sensitivity, and baseline characteristic. We also investigated polymer-nanocomposites for improving detection of toluene and trichloroethylene. One nanocomposite was successful for real-time tracking of both chemicals inside filters and demonstrated that it could be scaled to meet Honeywell's needs. These sensors still require optimization of sensitivity and power. Phase II will focus on readying the chemosensitive materials and transducers for transition either through sales or licensing to a filter manufacturer. Specific Phase II aims are to (1) optimize and complete the development of the acetone, toluene, and TCE detectors; (2) deliver working prototypes to Honeywell for validation testing in their filter-test labs; (3) support Honeywell's wireless readout circuit and sensor integration development; and (4) develop a manufacturing and transition plan to support commercialization. Honeywell tested Seacoast's prototypes and our Phase I results were shared with their team. Honeywell is eager to support our Phase II to create Smart Respirators for the over 544,000 workers in the US chemical manufacturing industries.