Breathing Apparatus

The invention is further described by way of the illustrative examples with reference to the drawings, in which:

FIG. 1 is a schematic representation of a nonredundant sensor-controlled closed circuit mixed gas breathing apparatus of the present invention;

FIG. 2 is a lateral right hand sectional view of the integral buoyancy compensator/counterlung vest of the present invention with a unitary gas and liquid removal means;

FIG. 3 is a lateral right hand sectional view of the integral buoyancy compensator/counterlung vest of the present invention with separate gas and liquid removal means;

FIG. 4 is a top plan view of the counterlung of the present invention;

FIG. 5 is a graph illustrating the relationship between the user orientation angle and the static lung loading;

FIG. 6 is a perspective view of the breathing apparatus depicted in FIG. 1;

FIG. 7 is a front sectional view of the manual override control system of the present invention;

FIG. 8 is a schematic representation of a redundant bi-linear sensor-controlled closed circuit mixed gas breathing apparatus of the present invention;

FIG. 9 is a perspective view of the breathing apparatus depicted in FIG. 8;

FIG. 10 is a schematic representation of a fully-redundant breathing apparatus of the present invention;

FIG. 11 is a perspective view of the fully-redundant breathing apparatus depicted in FIG. 10.

The non-redundant sensor-controlled closed-circuit mixed-gas breathing apparatus of the present invention is schematically shown in FIG. 1. In accordance with the invention, there is provided a mouthpiece 3 into which the user breathes. An example of such a mouthpiece which may be used is the subject of my co-pending application Ser. No. 07/340,250 entitled "BREATHING APPARATUS MOUTHPIECE" filed on Apr. 19, 1989 and which is incorporated herein by reference. The flow of the breathing gas is constrained in the direction of the arrow by checkvalves 35 and 36 on the exhale and inhale sides of mouthpiece 3 respectively. Upon exhalation, the flow is preferably directed through hose 5 and into manifold 6 where it is routed by means of an internal "T" joint into the user's right hand counterlung. The counterlung may have any desired configuration or shape. Preferably the counterlung is split into counterlungs 1 and 11, each having a capacity of about one-half the volume of the user's lung capacity. The exhaled gas in excess of that held by counterlung 1 flows through hose 8 and into a chamber 29 which contains a carbon dioxide removal system. The cleansed gas, from which the carbon dioxide has been removed, then continues through hose 9, into manifold 10, and consequently into counterlung 11, which comprises the second half of the counterlung volume. This completes the exhalation cycle.

Upon inhalation, the gas in the left hand counterlung 11 is breathed through hose 12, then checkvalve 36, into mouthpiece 3 until counterlung 11 collapses. At this point, the volume of counterlung 1 is drawn through the carbon dioxide removal system 29, through hose 9, and directly through manifold 10 to hose 12 to mouthpiece 3.

During normal operation of the apparatus oxygen is metabolized by the user and converted to carbon dioxide which is subsequently removed from the system. Provided depth is not increasing during this time, the partial pressure of oxygen will begin to decrease. An increase in depth results in an increase in the pressure, which includes an increase in the partial pressure of oxygen. The partial pressure of oxygen should be maintained between 0.14 and 1.4 atmospheres. A partial pressure of oxygen below 0.14 atmospheres will result in hypoxia while a partial pressure of oxygen above 1.4 atmospheres leads to central nervous system oxygen toxicity. Advantageously, an electrochemical sensor 30, or series of said sensors, may be provided to detect the partial pressure of oxygen and to provide information to an electronic decision making module 28, which may be either analog or digital. The sensor 30 is set at a pre-established setpoint, commonly 0.7 atmospheres, at which oxygen addition is triggered. When the partial pressure of oxygen indicated by sensor(s) 30 falls below this pre-established setpoint the electronic control system 28 opens an electronic valve 27, which subsequently permits a quantity of pressurized oxygen to be sent through a small diameter low pressure supply line 20 to the manual override control panel 17.

The pressurized oxygen supply which feeds electronic valve 27 preferably consists of a high pressure vessel 23, a shut-off valve 22, and a first regulator 21 which reduces the pressure sufficiently so that electronic valve 27 is operable. The pressure is typically reduced to about 10 bars. The flow of oxygen from electronic valve 27 to the breathing circuit may be stopped by the user at any time by closing manual valve 32 advantageously located in the center of the manual override panel 17, irrespective of whether valve 27 is open. This feature permits the user to take direct intervention and stop the flow of oxygen to the breathing circuit in the event of a failure of electronic valve 27 in the open position. Such failures in prior art devices can lead to the death of the user. A second low pressure oxygen line 18 carries oxygen directly from regulator 21 to the manual override control panel 17. There, lever 33, when depressed, actuates a manually operated valve which manually adds gas to the system and thus permits the user to continue operation in closed-circuit mode, even following failure of electronic valve 27. In a similar manner, diluent gas is provided for the system by means of a high pressure vessel 24, a shut-off valve 25, and a regulator 26 which reduces the pressure to a value typically supplied to second stage open-circuit regulators. This is typically about 10 bars. The diluent gas consists of oxygen and an inert, nontoxic gas or mixture thereof. Thus, the diluent gas may be air, a helium-oxygen mixture, nitrox, which is a combination of oxygen and nitrogen in proportions other than that of air, trimix, which is a combination of oxygen, nitrogen and helium, and the like.

Two low pressure, small diameter lines carry gas to the breathing circuit from the diluent supply. Line 34 connects the low pressure diluent output from regulator 26 with an adjustable, in-line control valve 4 which permits the user to adjust the pressure drop required to open a second stage open-circuit valve, which is integrated into mouthpiece 3. Adjustable valve 4 permits complete shut-off of the flow through feed line 34 thus allowing the user to stop a free flowing second stage valve in mouthpiece 3 without having to close the high pressure shut-off valve 25. Furthermore, an additional low pressure line 19 connects diluent regulator 26 to the manual override control panel 17. By depressing lever 31 the user can manually add diluent to the system irrespective of whether or not adjustable valve 4 is closed.

The output from the manual override control, (which includes oxygen delivered from electronic valve 27), is sent via a single low pressure line 7 to manifold 6 where it is injected into the closed-circuit process loop. Entry of the oxygen and diluent supply gases at this location ensures complete mixing prior to inhalation by the diver. Incomplete mixing can result in pockets of gas where there is too much or too little oxygen, thus possibly leading to hypoxia or oxygen toxicity.

From the above discussion, it is shown that there are two completely independent paths for both diluent and oxygen addition to the system, any of which can be shutdown or opened by means of manually controllable valves which are mounted on the user's chest, within easy reach and readily accessible.

A key safety feature of the present invention is that, in the event of total flooding of the closed-circuit process circuit described above, the user converts mouthpiece 3 to function as an open-circuit second stage regulator with no connection to the closed-circuit process loop. Use of a relatively large capacity diluent bottle 24, or an external diluent supply, can provide a significant amount of time for use of this integral open circuit bailout system, thus enabling the user to effect a recovery from the closed-circuit malfunction. This feature makes possible the safe use of the breathing apparatus of the present invention for general sport diving, where significant decompression is generally not a factor and where the open-circuit bailout system would permit a direct, safe ascent to the surface in the event of a failure of the closed-circuit portion of the apparatus.

The counterlungs consist of a closed volume which receives the exhalation gases and from which the inhalation gases are drawn. Advantageously, counterlungs 1 and 11 can be designed to form the front panels of a vest.

For diving use, the back panel of the same vest may advantageously be comprised of a buoyancy compensator 13 which is fabricated in a horseshoe shape not unlike that of a common back mounted buoyancy compensator used for open-circuit diving, except that it forms an integral portion of a hybrid vest. The buoyancy compensator portion of the vest is equipped with an oral/automatic inflator hose 15 for which low pressure diluent gas is supplied by low pressure line 16. Feed line 16 may either be connected to diluent regulator 26, or to an auxiliary external inflator bottle and regulator, not shown. Since both counterlungs 1 and 11, as well as buoyancy compensator 13 could burst due to expansion of gases during ascent, pressure relief valves 2 and 14 are provided for venting of the counterlungs and buoyancy compensator portions of the vest, respectively.

FIG. 2 illustrates a lateral right hand view of such an integral buoyancy compensator/counterlung vest. The counterlung 1 is comprised of a flexible impermeable gas bag 37, which may be fabricated from any known material exhibiting the properties of flexibility and impermeability, such as latex rubber, neoprene rubber, urethane, or the like. Advantageously, gas bag 37 is protected by shell 38 which can be constructed from either a rigid material, such as injection molded plastic, or from a rugged flexible cloth, such as cordura nylon. The purpose of outer shell 38 is to protect gas bag 37 from puncture which would lead to subsequent flooding of the closed-circuit process system. In the event that protective shell 38 is constructed in a rigid form, vent holes are provided such that, when diving, the surrounding water may easily enter and leave the protective shell as the gas bag expands and contracts during breathing.

As shown in FIG. 2, counterlung 1 preferably forms the right hand front side of a vest to be worn by the diver. At the top of the diver's shoulder manifold 6 penetrates, and is sealingly connected to the internal gas bag 37, such that exhaled gas delivered through hose 5 may enter the gas bag. Manifold 6 contains an internal "T" joint configuration such that exhaled gas in excess of that required to fill gas bag 37 may pass directly through said manifold and into hose 8 which carries exhaled gas to carbon dioxide sorubber 29, depicted in FIG. 1. Thus, only one penetration of the gas bag 37 is required to permit ingress and egress of the gases.

Because the gases contained in gas bag 37 will expand when the outside ambient pressure is reduced, such as when a diver returns to the surface from depth or the user ascends into a higher altitude, an overpressure checkvalve 2 is provided to prevent bursting of gas bag 37. It may be noted that checkvalve 2 is advantageously located at the base of counterlung 1.

During general operation of closed-circuit diving apparatus it is not unusual for small amounts of water to seep into the mouthpiece, whereupon it is transported down the exhale hose 5 and into counterlung 1. The amount of water entering in this manner during a prolonged dive can be significant. Preferably checkvalve 2 is provided to automatically vent any water which has collected as the diver ascends and the gas in counterlung 1 expands to the point where checkvalve 2 is triggered to vent the overpressure. If checkvalve 2 is provided with an adjustable tension capability the diver may periodically lower the opening pressure for the checkvalve and manually compress counterlung 1 in order to expel the collected water.

Advantageously an integral buoyancy compensation unit 13 forms the back side of the vest when counterlung 1 forms the front portion of the vest with a slight overlap at the shoulder. Buoyancy compensator 13 may be fabricated in a manner analogous to that commonly used in the manufacture of back-mounted horseshoe shaped buoyancy compensators which include a flexible impermeable internal gas bag 39 and a flexible protective outer shell 40 both of which may be fabricated from the materials described above for counterlung 1. Buoyancy compensator 13 is attached to counterlung 1 as shown in FIG. 2 near the back of the diver's shoulder. The connection may be accomplished by any suitable means, such as by sewing the two outer shells 38 and 40 along the overlap area when flexible material is used for both protective shells, and by means of grommet holes and lacing where shell 38 is fabricated from a rigid material.

A variation of the buoyancy compensator/counterlung vest of FIG. 2 is shown in FIG. 3 wherein checkvalve 2 is located near the diver's shoulder and a removable watertight canister 42 containing a moisture absorbing material is sealingly connected to penetration 41 which in itself penetrates and is sealingly connected to gas bag 37. This system, though less elegant than that shown in FIG. 2, since it involves three penetrations of gas bag 37 instead of two, allows for automatic removal of water from the counterlung without intervention from the diver. Absorbent cartridge 42 may be replaced between dives on the surface in a quick and easy manner. Checkvalve 2 must still be retained to prevent bursting of the counterlung 1 upon ascent from depth. Checkvalves for both counterlungs are not necessary as a single checkvalve 2 can control overpressure for both counterlung 1 as well as counterlung 11.

The counterlungs 1 and 11, as shown in FIG. 4, are preferably tapered in a specific manner. The segment of the counterlung of width 43 and length 46 extends behind diver's shoulder line 49. This is shown in FIGS. 2 and 3 as the short section of counterlung 1 which overlaps buoyancy compensator 13. A second segment extends from the diver's shoulder to a point partway down the diver's chest and contained within width 44 and length 47. A final, wider segment, bounded by width 45 and length 48 extends down the diver's chest below the second segment. Widths 43 through 45 are measured when gas bag 37 is laid flat. The circumference of the inflated gas bag in any given segment is thus 2 times the width value specified by widths 43, 44, or 45.

Referring to FIG. 5, for general diving operations a diver orientation angle 50 of between -30 degrees (head-down) to +120 degrees (leaning backward from vertical, looking upward) covers the entire range of normal and expected situations. Static lung loading 53 is equal to the difference in centimeters of water between the diver's suprasternal notch 51 and the center of gravity of the counterlung 52. As stated previously, it is highly desirable to have a slightly positive static lung loading, generally between 0 to +10 centimeters of water to reduce the breathing resistance and thus achieve easy work-of-breathing. An optimization computer program may be written which minimizes the static lung loading 53 throughout this regime of diver orientation angles by proper choice of counterlung dimensions 43 through 48.

For example, for a total counterlung capacity (both counterlungs 1 and 11) of 7 liters, an optimization to minimize static lung loading results in widths 43, 44, and 45, respectively, 10.2, 11.4, and 17.8 centimeters and lengths 46, 47, and 48, respectively, are 5.3, 22, and 24 centimeters. At the end of exhalation these dimensions will produce the curve plotted in FIG. 5 for static lung loading 53 versus diver orientation angle 50. From this it can be determined that the static lung loading is well within the desired upper 54 and lower 55 limits. It is desirable to design the counterlung such that static lung loading at the end of exhalation is shifted towards the upper limit 54, as shown by the curve plotted in FIG. 5 and as exemplified by the set of dimensions previously described, since the static lung loading will decrease slightly upon inspiration as the counterlung collapses. Significant extension of the counterlung segment bounded by width 43 and length 46 down the back side of the vest is non-productive, as this significantly decreases the positive static lung loading within the diver orientation angle regime desired by most divers.

It is to be noted that the counterlungs can be optimized for other diver orientation angles so that the static lung loading is at a minimum. Thus for example, where a diver is at an orientation angle of 180.degree. degrees, such as would be used for work where a diver is underneath a ship doing repair work, counterlung dimension 46 may be extended in such a manner as to minimize the static lung loading.

For other uses the counterlung dimensions and placement may be adjusted. Thus, for example, for use in rescue work or in toxic environments at approximately atmospheric pressure, the location of the counterlung is not of the paramount importance that it is with diving work or other work under pressure. Thus, the counterlung may be located anywhere, although for convenience the vest form is best.

For deep space exploration work, the present invention may be used without separate independent counterlungs. Instead, the inside volume of the space suit serves as the counterlung.

For high altitude use, such as in mountain climbing, the counterlungs in a vest form, may be worn under the parka and other outer wear gear. This eliminates the internal frost buildup that has been a problem with known rebreathers for high altitude use.

FIG. 6 is a perspective view of a physical rebreather incorporating the buoyancy compensator/counterlung vest thus far described as well as the special mouthpiece 3 and manual override control system 17 which will now be described in detail. As depicted in FIG. 6, there may be provided flexible utility pockets 57 and 58, which advantageously may be used to protect overpressure checkvalve 2 from abrasion.

The manual override control system is illustrated in FIGS. 1 and 7. Preferably low pressure flexible hoses 18, 20 and 19 deliver direct oxygen from oxygen regulator 21, automatic control oxygen from electronic valve 27, and direct diluent from diluent regulator 26, respectively, to the bulkhead of case 17. Internal piping 82, which may be either flexible or rigid small diameter tubing, transfers gas from lines 18, 20, and 19 to control mechanisms. Line 18 carries oxygen to a normally closed, spring loaded valve 77 of a type that is commonly available. At the user's discretion, lever 33, which pivots on hinge 75, is depressed, thus opening valve 77 and permitting the passage of oxygen. In a similar manner, line 19 carries diluent to a normally closed, spring loaded valve 78. When lever 31, which pivots on hinge 76, is depressed, valve 78 is opened permitting the passage of diluent gas. Line 20 carries oxygen from the electronic oxygen addition valve 27 to a manually operable inline shut-off valve 32 which is left in the open position during normal conditions. It should be noted that valve 32, which is a one-quarter turn on-off valve commonly available, permits the user to rapidly stop the flow of oxygen from the electronic oxygen addition valve 27 in the event of a failure of valve 27 in the open position. The outputs of valves 32, 77 and 78 are piped such that only one common output 7 leaves the manual override control box 17. It should be also noted that levers 33 and 31 may be equipped with identification knobs 79 and 80, respectively, which permit the user to distinguish the oxygen and diluent addition levers by touch. For example, a knurled knob 79 may be used to indicate oxygen, while a hexagonal bar 80 may be used to indicate diluent. Other valves and means for regulating the gas flow may be used.

The second embodiment of the invention, the bi-linear redundant mixed gas breathing apparatus, is schematically illustrated in FIG. 8.

The component numbers are the same for all figures. The addition of the letters A or B to a component number indicates which of the closed-circuit systems, either system A or system B, is referred to.

This closed-circuit system has several key characteristics which distinguish this system from the nonredundant systems previously described. First, because of the compact shape of counterlungs 1 and 11, and because they principally occupy space on the user's chest and are generally not used simultaneously, it is possible to construct a hybrid vest in which the counterlungs from the two separate systems may be almost totally overlapped with the exception of their respective manifold ports 6 and 10. This permits the construction of a dual-system of independent split counterlungs which, together with a single buoyancy compensator 13 as previously described, comprise a vest that occupies a volume only nominally larger than that for the non-redundant system, as depicted in FIGS. 1 and 6. Preferably the two counterlungs comprising each vest panel, for example, 1A and 11B in FIG. 8 are fabricated such that they act structurally as a single unit. This may be accomplished, in the case of a flexible protective counterlung shell 38 by sewing or otherwise fastening the outer protective shells 38 for counterlungs 1A and 11B along the dashed and solid lines depicting the inner edge of counterlung 11B and the left-most edge of counterlung 1A, respectively, in FIG. 8.

The two independent closed-circuit systems A and B may be constructed with either counter-rotational flow or corotational flow. Counter-rotational flow, as indicated by the arrows in FIG. 8, preserves external symmetry from the user's point of view, thus cleanly separating the functional operation of the two systems. This characteristic is further illustrated as follows. The exhalation counterlung 1A for system A is shown in FIG. 8 as the outer portion of the right hand vest panel. The inner portion of this same vest panel is comprised of the inhalation counterlung 11B for system B. In a similar manner, exhalation counterlung 1B for system B forms the outer portion of the left hand vest panel. The inhalation counterlung 11A forms the interior portion of the left hand vest panel. Because the exhalation counterlungs for both system A and system B comprise the outer elements of the vest panels, overpressure checkvalves 2A and 2B may be symmetrically placed as shown in FIG. 8. In addition, manual override panels 17A and 17B are preferably mounted on the exterior panels 1A and 1B, respectively. FIG. 9 shows a perspective view of the physical invention bounded by the dashed box in FIG. 8. In FIG. 9, it is evident in order to implement the architecture illustrated in FIG. 8, that inhalation hose 12A and exhalation hose 5B must cross.

From a system survival standpoint, the bi-linear redundant system illustrated in FIG. 9 provides a system survival probability in closed-circuit mode of approximately an order of magnitude greater than that for a non-redundant system, such as shown in FIG. 1. In the event of a failure of system A, for example due to flooding of system A, the user may simply switch from mouthpiece 3A to mouthpiece 3B and continue in a fully closed-circuit mode. Furthermore, in the event of failure of both closed-circuit systems, the user still has two independent diluent supplies which may be accessed in open circuit mode.

The second embodiment of the invention shown in FIG. 8, although substantially safer than any closed-circuit diving apparatus described in the prior art, may be further improved from a safety standpoint as described below.

The third embodiment of the invention, a fully redundant closed-circuit diving apparatus, is depicted in FIG. 10. This differs from the second embodiment of the invention presented in FIG. 8 in several ways. First, the flow in the two independent closed-circuit systems A and B must be corotational, as indicated by the arrows in FIG. 10. The reason for this requirement is that the exhaled gases from both mouthpieces are now connected to an exhalation routing manifold 88A, mounted on the diver's right shoulder, which permits the diver to re-route the flow of the exhaled gas from either of mouthpiece 3A or mouthpiece 3B to its opposite system gas processing unit. A similar inhalation routing manifold 88B is provided on the diver's left shoulder such that the output from either gas processing system can be routed to any of mouthpieces 3A or 3B. For the sake of discussion, the terms "left shoulder" and "right shoulder" are used to describe the operation of the breathing apparatus of the present invention and can be interchanged, provided correct continuity is maintained with respect to gas flow direction.

These manifolds are further described in detail in my co-pending application Ser. No. 07/340,260 filed on Apr. 19, 1989 and incorporated herein by reference.

These routing manifolds allow the user to gain significant extra time by cross routing of the gases. For example, if all supply gases in system A have been exhausted, yet the carbon dioxide scrubber 29A still has useful life, the gases from mouthpiece 3B may be routed into carbon dioxide scrubber 29A, provided supply gas still exists in system B. The inhalation routing manifold 88B is identical to exhalation routing manifold with the exception that the gas addition bulkhead penetrations are not required. Also, both mouthpieces 3A and 3B may be routed to access carbon dioxide removal and oxygen control system B simultaneously. The exhalation flow from either mouthpiece may be completely blocked off. This may be desirable if a leak has occurred in one mouthpiece but the user needs the extra breathing time afforded by making use of the corresponding carbon dioxide removal system by means of the other mouthpiece. Alternate routing may include from one mouthpiece to the other carbon dioxide processing system. Valve positions for the inhalation manifold 88B are identical to those for manifold 88A. These valves are identified as 86C and 86D in FIG. 11, a perspective view of the fully redundant embodiment of the invention.

In FIG. 11 it should be noted that although overpressure checkvalve 2B is located at the bottom of counterlung 1B, it could equally well be located on counterlung 11B. In FIG. 11 both overpressure checkvalves 2A and 2B may be protected from abrasion by being placed underneath flexible utility pocket 57. An additional flexible utility pocket 58 may be provided at the bottom of counterlung 11A.

It should be understood that the foregoing disclosure relates only to preferred embodiments of the invention and that numerous modifications or alterations may be made therein without departing from the spirit and scope of the invention as set forth in the appended claims.