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

项目概要/摘要：呼吸器口罩被许多行业的工人佩戴，如石油和天然气， 金属加工、危险材料以及化学研究和制造。普通有机蒸汽（OV） 呼吸器面罩采用定期更换的过滤罐或滤筒，根据不同的情况， 保护等级和制造商。可更换过滤器的使用寿命是高度可变的，这取决于 佩戴者的肺活量、化学品暴露的类型和浓度以及环境因素，并且可能在 从几分钟到几天。目前还没有确定的方法来识别即将崩溃的保护 并且没有能够可靠地警告佩戴者即将突破的“智能”过滤筒。 在此SBIR中，Seacoast Science，Inc.正在开发嵌入式探测器，以创造新的“智能呼吸器”， 由霍尼韦尔安全产品公司提供的规范指导，检测使用寿命终止（EOSL）， OV滤芯。霍尼韦尔正在开发一种无线接口，它将与传感器连接， 在化学品泄漏之前向用户提供警告。这些实时探测器将测量 与各种高风险职业相关的化学蒸汽浓度。这是第一步 到为各种化学工业的工人创造智能个人防护设备。最后， 来自智能墨盒的数据可以无线连接到曝光/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，Seacoast确定了应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规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 满足霍尼韦尔对尺寸、功率、重量、灵敏度和基线特性的所有要求。我们也 研究了聚合物纳米复合材料，用于改善甲苯和三氯乙烯的检测。一 纳米复合材料成功地实时跟踪了过滤器内的两种化学物质，并证明它 可以扩展以满足霍尼韦尔的需求。这些传感器仍然需要优化灵敏度和功率。 第二阶段将集中在准备化学敏感材料和传感器的过渡，通过销售， 或许可给过滤器制造商。第二阶段的具体目标是：（1）优化和完成 丙酮、甲苯和TCE检测器;（2）将工作原型交付给霍尼韦尔进行验证测试 他们的滤波器测试实验室;（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） 制定生产和过渡计划，以支持商业化。霍尼韦尔测试了海岸的 原型和我们的第一阶段结果与他们的团队分享。霍尼韦尔渴望支持我们的第二阶段， 为美国化学制造业的544，000多名工人创造智能呼吸器。

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.