Characteristics of face seal leakage in filtering facepieces.

Several studies have found that aerosol size, testing method, leak size, leak position, sampling probe location, and the mixing condition inside the respirator affect the results of fit factor measurements. This study focuses on the effect of leak shape and filter resistance because leaks have been reported to vary in shape from circular to slit-like. Four leaks of different shape but the same cross-sectional area were used to study their effect on aerosol penetration. Dust-mist and high-efficiency particulate air filtering facepieces provided different filter resistances. An aerodynamic particle sizer and a laser aerosol spectrometer were used to measure the particle size-dependent aerosol concentrations inside and outside the respirators. The filtering facepieces were sealed to a mannequin and artificial leaks were inserted near the right cheek. Aerosol penetration was measured for five flow rates ranging from 5 to 100 L/min. The pressure drop across the mask was monitored with an inclined manometer. At a given pressure differential, a slit-like leak and multiple circular leaks have been found to pass less aerosols than a single circular leak of equal cross-sectional area because the leak flow decreases with an increase in leak shape complexity. If there is substantial lack of face seal fit and the breathing rate is low, a HEPA respirator may provide less protection than a dust-mist respirator because the pressure drop is considerably higher for a HEPA respirator, resulting in more aerosol flow through the leak.     

Total inward leakage of nanoparticles through filtering facepiece respirators

Nanoparticle (<100 nm size) exposure in workplaces is a major concern because of the potential impact on human health. National Institute for Occupational Safety and Health (NIOSH)-approved particulate respirators are recommended for protection against nanoparticles based on their filtration efficiency at sealed conditions. Concerns have been raised on the lack of information for face seal leakage of nanoparticles, compromising respiratory protection in workplaces. To address this issue, filter penetration and total inward leakage (TIL) through artificial leaks were measured for NIOSH-approved N95 and P100 and European certified Conformit'e Europe'en-marked FFP2 and FFP3 filtering facepiece respirator models sealed to a breathing manikin kept inside a closed chamber. Monodisperse sucrose aerosols (8-80 nm size) generated by electrospray or polydisperse NaCl aerosols (20-1000 nm size) produced by atomization were passed into the chamber. Filter penetration and TIL were measured at 20, 30, and 40 l min(-1) breathing flow rates. The most penetrating particle size (MPPS) was ～50 nm and filter penetrations for 50 and 100 nm size particles were markedly higher than the penetrations for 8 and 400 nm size particles. Filter penetrations increased with increasing flow rates. With artificially introduced leaks, the TIL values for all size particles increased with increasing leak sizes. With relatively smaller size leaks, the TIL measured for 50 nm size particles was ～2-fold higher than the values for 8 and 400 nm size particles indicating that the TIL for the most penetrating particles was higher than for smaller and larger size particles. The data indicate that higher concentration of nanoparticles could occur inside the breathing zone of respirators in workplaces where nanoparticles in the MPPS range are present, when leakage is minimal compared to filter penetration. The TIL/penetration ratios obtained for 400 nm size particles were larger than the ratios obtained for 50 nm size particles at the three different flow rates and leak sizes indicating that face seal leakage, not filter penetration, contributing to the TIL for larger size particles. Further studies on face seal leakage of nanoparticles for respirator users in workplaces are needed to better understand the respiratory protection against nanoparticle exposure.     

Aerosol penetration through filtering facepieces and respirator cartridges.

Air-purifying respirators must be certified following the National Institute for Occupational Safety and Health (NIOSH) filter test criteria (30 CFR 11). The criteria specify a range for the mean particle size and the measure of spread permissible for the test aerosol. The authors' experiments have shown that aerosol penetration as a function of particle size differs considerably among certified respirators of the same type. Filtering facepieces (disposable respirators) and cartridges of the dust-mist, dust-mist-fume, and high-efficiency particulate air type were tested. The respirators were sealed to mannequins in a test chamber. The aerosol concentrations inside and outside the respirator were measured by an aerodynamic particle sizer and a laser aerosol spectrometer over a particle size range of 0.1 to 15 microns. Five flow rates ranging from 5 to 100 L/min were used to study flow dependency. The aerosol penetration through the filters is presented as a function of particle size. Aerosol penetration and pressure drop are combined to express the performance of each filter in terms of "quality factor." Under the same test conditions, the quality factor of one respirator may be as much as 6.6 times more than that of another respirator of the same type. The filter quality factor has a greater aerosol size dependency as airflow and aerosol size increase. In general, cartridges have a larger surface area than filtering facepieces but not necessarily lower filter penetration or higher filter quality.(ABSTRACT TRUNCATED AT 250 WORDS)     

Evaluation of respirator filters for asbestos fibers

Fiber aerosols are known to have different aerodynamic behaviors than spherical particles and usually carry higher electrostatic charges. We investigated the effects of flow rate and charge status of filter cartridges on the penetration of spherical and fiber aerosols. Four types of test respirator filters were selected: two for passive respirators, one for a powered respirator, and one disposable respirator. Surface charges on respirator filters were determined using a noncontact field electrostatic field meter. Penetration tests were performed for filter cartridges before and after charge neutralization. The surface charge measurements on the respirator filters showed that some filters, including those used in disposable face masks, are charged to enhance the collection efficiency. Only high-efficiency particulate air filters performed consistently for both spherical test aerosols and the three types of asbestos fibers. The surface charge potential of filter cartridges and flow rate did not appear to affect the performance of these filters. In contrast to the high-efficiency filters, the aerosol penetration performance of low-efficiency filters and face masks deteriorated when the charge potential on the filter was removed. Our data also showed that the surface charges decreased in a high-temperature, high-humidity environment and disappeared after 1 week. Deposition of spherical particles and fibers in the charged disposable facemask filter was enhanced. For charged-neutralized, low-efficiency filter cartridges, asbestos fibers may penetrate more than spherical particles with a mean particle size of 0.3 microm diameter.     

Filter performance of n99 and n95 facepiece respirators against viruses and ultrafine particles

The performance of three filtering facepiece respirators (two models of N99 and one N95) challenged with an inert aerosol (NaCl) and three virus aerosols (enterobacteriophages MS2 and T4 and Bacillus subtilis phage)-all with significant ultrafine components-was examined using a manikin-based protocol with respirators sealed on manikins. Three inhalation flow rates, 30, 85, and 150 l min(-1), were tested. The filter penetration and the quality factor were determined. Between-respirator and within-respirator comparisons of penetration values were performed. At the most penetrating particle size (MPPS), >3% of MS2 virions penetrated through filters of both N99 models at an inhalation flow rate of 85 l min(-1). Inhalation airflow had a significant effect upon particle penetration through the tested respirator filters. The filter quality factor was found suitable for making relative performance comparisons. The MPPS for challenge aerosols was <0.1 mum in electrical mobility diameter for all tested respirators. Mean particle penetration (by count) was significantly increased when the size fraction of <0.1 mum was included as compared to particles >0.1 mum. The filtration performance of the N95 respirator approached that of the two models of N99 over the range of particle sizes tested ( approximately 0.02 to 0.5 mum). Filter penetration of the tested biological aerosols did not exceed that of inert NaCl aerosol. The results suggest that inert NaCl aerosols may generally be appropriate for modeling filter penetration of similarly sized virions.     

The effect of pressure drop on respirator faceseal leakage

Users of particulate air-purifying respirators are typically told to change their filters when breathing resistance becomes uncomfortable. It has been proposed that a noticeable increase in breathing resistance (pressure drop) may increase airflow through respirator faceseal leaks. This logic has been extended to suggest that respirator user exposure to contaminants may increase because of this theoretical increase in air leakage. Procedures similar to those of previous investigators were used to study this issue. Repeated faceseal leak rate measurements were made at -5.6 through -20.1 mm water pressure drops across the faceseal. Subjects were divided into two groups, representing acceptable fit or unacceptable fit, based on leak rate criteria prescribed by the Occupational Safety and Health Administration (OSHA). Subjects with acceptable fit did not experience an increase in faceseal leak rate with increased pressure drop. Leak rates for subjects with unacceptable fit were highly variable and did not show an association with pressure drop. Results of this study do not support the concept of increased faceseal leakage with increased pressure drop. The evidence does not suggest increased risk of contaminant exposure through the face seal as pressure drop increases.     

Performance of respirator filters using quality factor in Korea

A respirator filter of good quality has not only high aerosol collection efficiency but also low air resistance. "Quality factor", which is expressed with aerosol penetration and pressure drop, can be used to rank the performance of respirator filters within the same category. This study focuses on evaluating several respirator filters which are widely used in Korea using quality factor. Two mechanical filters and three filtering facepieces made by different manufacturers were measured aerosol penetrations and pressure drops by an automatic filter tester (CertiTest Model 8110, TSI Inc., St. Paul, USA) at four flow rates of 10, 32, 64 and 85 L/min. NaCl aerosols used were reported to be mean size of 0.1 microm and geometric standard deviation of <1.9. The penetrations and pressure drops of all filters have strong flow rate dependency. The filter quality factors decrease sharply as flow rates are increased. The mechanical filter S and filtering facepiece M are shown better filter quality than others in the same category. Since some certified filters are found to be inappropriate in the workplace exposed to fume, this result suggests that the current certified filter test protocol for respirators should be changed for the new protocol using smaller aerosols.     

A Quantitative Assessment of the Total Inward Leakage of NaCl Aerosol Representing Submicron-Size Bioaerosol Through N95 Filtering Facepiece Respirators and Surgical Masks

Respiratory protection provided by a particulate respirator is a function of particle penetration through filter media and through faceseal leakage. Faceseal leakage largely contributes to the penetration of particles through a respirator and compromises protection. When faceseal leaks arise, filter penetration is assumed to be negligible. The contribution of filter penetration and faceseal leakage to total inward leakage (TIL) of submicron-size bioaerosols is not well studied. To address this issue, TIL values for two N95 filtering facepiece respirator (FFR) models and two surgical mask (SM) models sealed to a manikin were measured at 8 L and 40 L breathing minute volumes with different artificial leak sizes. TIL values for different size (20–800 nm, electrical mobility diameter) NaCl particles representing submicron-size bioaerosols were measured using a scanning mobility particle sizer. Efficiency of filtering devices was assessed by measuring the penetration against NaCl aerosol similar to the method used for NIOSH particulate filter certification. Results showed that the most penetrating particle size (MPPS) was ～45 nm for both N95 FFR models and one of the two SM models, and ～350 nm for the other SM model at sealed condition with no leaks as well as with different leak sizes. TIL values increased with increasing leak sizes and breathing minute volumes. Relatively, higher efficiency N95 and SM models showed lower TIL values. Filter efficiency of FFRs and SMs influenced the TIL at different flow rates and leak sizes. Overall, the data indicate that good fitting higher-efficiency FFRs may offer higher protection against submicron-size bioaerosols.     

Noninvasive, quantitative respirator fit testing through dynamic pressure measurement

A new method has been invented for the noninvasive and quantitative determination of fit for a respirator. The test takes a few seconds and requires less expensive instrumentation than presently used for invasive testing. In this test, the breath is held at a negative pressure for a few seconds, and the leak-induced pressure decay inside the respirator cavity is monitored. A dynamic pressure sensor is attached to a modified cartridge of an air-purifying respirator or built into the respirator body or into the air supply line of an air-supplied respirator. The method is noninvasive in that the modified cartridge can be mounted onto any air-purifying respirator. The pressure decay during testing quantifies the airflow entered through the leak site. An equation has been determined which gives the air leakage as a function of pressure decay slope, respirator volume and the pressure differential during actual wear--all of which are determined by the dynamic pressure sensor. Thus, the ratio of air inhaled through the filters or via the air supply line to the leak rate is a measure of respirator fit, independent of aerosol deposition in the lung and aerosol distribution in the respirator cavity as found for quantitative fit testing with aerosols. The new method is shown to be independent of leak and sensor locations. The concentration and distribution of aerosols entered through the leak site is dependent only on the physical dimensions of the leak site and the air velocity in it, which can be determined independently.(ABSTRACT TRUNCATED AT 250 WORDS)     

Nanoparticle penetration through filter media and leakage through face seal interface of N95 filtering facepiece respirators

National Institute for Occupational Safety and Health recommends the use of particulate respirators for protection against nanoparticles (<100 nm size). Protection afforded by a filtering facepiece particulate respirator is a function of the filter efficiency and the leakage through the face-to-facepiece seal. The combination of particle penetration through filter media and particle leakage through face seal and any component interfaces is considered as total inward leakage (TIL). Although the mechanisms and extent of nanoparticle penetration through filter media have been well documented, information concerning nanoparticle leakage through face seal is lacking. A previous study in our laboratory measured filter penetration and TIL for specific size particles. The results showed higher filter penetration and TIL for 50 nm size particles, i.e. the most penetrating particle size (MPPS) than for 8 and 400 nm size particles. To better understand the significance of particle penetration through filter media and through face seal leakage, this study was expanded to measure filter penetration at sealed condition and TIL with artificially introduced leaks for 20-800 nm particles at 8-40 l minute volumes for four N95 models of filtering facepiece respirators (FFRs) using a breathing manikin. Results showed that the MPPS was ~45 nm for all four respirator models. Filter penetration for 45 nm size particles was significantly (P < 0.05) higher than the values for 400 nm size particles. A consistent increase in filter penetrations for 45 and 400 nm size particles was obtained with increasing breathing minute volumes. Artificial leakage of test aerosols (mode size ~75 nm) through increasing size holes near the sealing area of FFRs showed higher TIL values for 45 nm size particles at different minute volumes, indicating that the induced leakage allows the test aerosols, regardless of particle size, inside the FFR, while filter penetration determines the TIL for different size particles. TIL values obtained for 45 nm size particles were significantly (P < 0.05) higher than the values obtained for 400 nm size particles for all four models. Models with relatively small filter penetration values showed lower TIL values than the models with higher filter penetrations at smaller leak sizes indicating the dependence of TIL values on filter penetration. When the electrostatic charge was removed, the FFRs showed a shift in the MPPS to ~150 nm with the same test aerosols (mode size ~75 nm) at different hole sizes and breathing minute volumes, confirming the interaction between filter penetration and face seal leakage processes. The shift in the MPPS from 45 to 150 nm for the charge removed filters indicates that mechanical filters may perform better against nanoparticles than electrostatic filters rated for the same filter efficiency. The results suggest that among the different size particles that enter inside the N95 respirators, relatively high concentration of the MPPS particles in the breathing zone of respirators can be expected in workplaces with high concentration of nanoparticles. Overall, the data obtained in the study suggest that good fitting respirators with lower filter penetration values would provide better protection against nanoparticles.     

What does respirator certification tell us about filtration of ultrafine particles?

Recent interest in exposures to ultrafine particles (less than 100 nm) in both environmental and occupational settings led the authors to question whether the protocols used to certify respirator filters provide adequate attention to ultrafine aerosols. The authors reviewed the particle size distribution of challenge aerosols and evaluated the aerosol measurement method currently employed in the National Institute for Occupational Safety and Health (NIOSH) particulate respirator certification protocol for its ability to measure the contribution of ultrafine particles to filter penetration. Also considered were the differences between mechanical and electrically charged (electret) filters in light of the most penetrating particle size. It was found that the sodium chloride (NaCl) and dioctylphthalate (DOP) aerosols currently used in respirator certification tests contain a significant fraction of particles in the ultrafine region. However, the photometric method deployed in the certification test is not capable of adequately measuring light scatter of particles below approximately 100 nm in diameter. Specifically, 68% (by count) and 8% (by mass) of the challenge NaCl aerosol particles and 10% (by count) and 0.3% (by mass) of the DOP particles below 100 nm do not significantly contribute to the filter penetration measurement. In addition, the most penetrating particle size for electret filters likely occurs at 100 nm or less under test conditions similar to those used in filter certification. The authors conclude, therefore, that the existing NIOSH certification protocol may not represent a worst-case assessment for electret filters because it has limited ability to determine the contribution of ultrafine aerosols, which include the most penetrating particle size for electret filters. Possible strategies to assess ultrafine particle penetration in the certification protocol are discussed.     

Particle size-dependent leakage and losses of aerosols in respirators

Measuring particle size-dependent leakage into and losses inside a respirator reveals the deposition mechanisms occurring at the leak site and the flow dynamics inside the respirator. This study investigated particle size-dependent leakage and deposition within the mask by examining the leakage into the mask for different hole locations, probe locations, hole shapes, hole lengths and hole sizes. The shape of the leak has an effect on particle size-dependent leakage. Probe and leak location tests indicated that not only does the total measured leakage change but also the size-dependence of the leakage changes depending on the leak and probe locations. When the leak site is in the chin area, the clean air entering through the filters at the chin helps to carry the inward leakage into the breathing zone. Particle size-dependent leakage does occur and is due to both inertial entry losses at the leak site and within the mask, and diffusional losses within the mask and leak site. Particle size-dependent curves change shape as the hole size changes with relatively more larger particles entering through the small hole size.     

Comparison of pressure drop and filtration efficiency of particulate respirators using welding fumes and sodium chloride

Respirators are used to help reduce exposure to a variety of contaminants in workplaces. Test aerosols used for certification of particulate respirators (PRs) include sodium chloride (NaCl), dioctyl phthalate, and paraffin oil. These aerosols are generally assumed to be worst case surrogates for aerosols found in the workplace. No data have been published to date on the performance of PRs with welding fumes, a hazardous aerosol that exists in real workplace settings. The aim of this study was to compare the performance of respirators and filters against a NaCl aerosol and a welding fume aerosol and determine whether or not a correlation between the two could be made. Fifteen commercial PRs and filters (seven filtering facepiece, two replaceable single-type filters, and six replaceable dual-type filters) were chosen for investigation. Four of the filtering facepiece respirators, one of the single-type filters, and all of the dual-type filters contained carbon to help reduce exposure to ozone and other vapors generated during the welding process. For the NaCl test, a modified National Institute for Occupational Safety and Health protocol was adopted for use with the TSI Model 8130 automated filter tester. For the welding fume test, welding fumes from mild steel flux-cored arcs were generated and measured with a SIBATA filter tester (AP-634A, Japan) and a manometer in the upstream and downstream sections of the test chamber. Size distributions of the two aerosols were measured using a scanning mobility particle sizer. Penetration and pressure drop were measured over a period of aerosol loading onto the respirator or filter. Photos and scanning electron microscope images of clean and exposed respirators were taken. The count median diameter (CMD) and mass median diameter (MMD) for the NaCl aerosol were smaller than the welding fumes (CMD: 74 versus 216 nm; MMD: 198 versus 528 nm, respectively). Initial penetration and peak penetration were higher with the NaCl aerosol. However, pressure drop increased much more rapidly in the welding fume test than the NaCl aerosol test. The data and images clearly show differences in performance trends between respirator models. Therefore, general correlations between NaCl and weld fume data could not be made. These findings suggest that respirators certified with a surrogate test aerosol such as NaCl are appropriate for filtering welding fume (based on penetration). However, some respirators may have a more rapid increase in pressure drop from the welding fume accumulating on the filter. Therefore, welders will need to choose which models are easier to breathe through for the duration of their use and replace respirators or filters according to the user instructions and local regulations.     

Filter quality of pleated filter cartridges

The performance of dust cartridge filters commonly used in dust masks and in room ventilation depends both on the collection efficiency of the filter material and the pressure drop across the filter. Currently, the optimization of filter design is based only on minimizing the pressure drop at a set velocity chosen by the manufacturer. The collection efficiency, an equally important factor, is rarely considered in the optimization process. In this work, a filter quality factor, which combines the collection efficiency and the pressure drop, is used as the optimization criterion for filter evaluation. Most respirator manufacturers pleat the filter to various extents to increase the filtration area in the limit space within the dust cartridge. Six sizes of filter holders were fabricated to hold just one pleat of filter, simulating six different pleat counts, ranging from 0.5 to 3.33 pleats cm(-1). The possible electrostatic charges on the filter were removed by dipping in isopropyl alcohol, and the air velocity is fixed at 100 cm s(-1). Liquid dicotylphthalate particles generated by a constant output atomizer were used as challenge aerosols to minimize particle loading effects. A scanning mobility particle sizer was used to measure the challenge aerosol number concentrations and size distributions upstream and downstream of the pleated filter. The pressure drop across the filter was monitored by using a calibrated pressure transducer. The results showed that the performance of pleated filters depend not only on the size of the particle but also on the pleat count of the pleated filter. Based on filter quality factor, the optimal pleat count (OPC) is always higher than that based on pressure drop by about 0.3-0.5 pleats cm(-1). For example, the OPC is 2.15 pleats cm(-1) from the standpoint of pressure drop, but for the highest filter quality factor, the pleated filter needed to have a pleat count of 2.65 pleats cm(-1) at particle diameter of 122 nm. From the aspect of filter quality factor, this study suggests that the respirator manufacturers should add approximately 0.5 pleats cm(-1) to the OPC derived from the generalized correlation curve for pleated filter design based on minimum pressure drop.     

Performance of dust respirators with facial seal leaks: II. Predictive model

A performance model for half-mask and single-use respirators is presented. It represents a possible alternative to field measurements of respirator performance. Experimental data on filter and leak performance given in Part I were used to develop a model that allows one to predict 1) the overall respirator penetration as a function of particle size for any work rate and 2) overall total mass penetration for any work rate and exposure aerosol-size distribution for a known respirator filter and facial seal leak condition. A simplified method based on general regression equations is presented that allows one to estimate these quantities based on QNFT (quantitative fit testing) measurements and a knowledge of the exposure aerosol-size distribution. Example calculations are given for a situation in which QNFT gives a fit factor of 50 for a half-mask with dust, fume and mist filter cartridges, but predicted protection factors for various use conditions range from 20 to 81 depending on exposure particle-size distribution and work rate of the wearer.     

Nanoparticle filtration performance of NIOSH-certified particulate air-purifying filtering facepiece respirators: evaluation by light scattering photometric and particle number-based test methods

National Institute for Occupational Safety and Health (NIOSH) certification test methods employ charge neutralized NaCl or dioctyl phthalate (DOP) aerosols to measure filter penetration levels of air-purifying particulate respirators photometrically using a TSI 8130 automated filter tester at 85 L/min. A previous study in our laboratory found that widely different filter penetration levels were measured for nanoparticles depending on whether a particle number (count)-based detector or a photometric detector was used. The purpose of this study was to better understand the influence of key test parameters, including filter media type, challenge aerosol size range, and detector system. Initial penetration levels for 17 models of NIOSH-approved N-, R-, and P-series filtering facepiece respirators were measured using the TSI 8130 photometric method and compared with the particle number-based penetration (obtained using two ultrafine condensation particle counters) for the same challenge aerosols generated by the TSI 8130. In general, the penetration obtained by the photometric method was less than the penetration obtained with the number-based method. Filter penetration was also measured for ambient room aerosols. Penetration measured by the TSI 8130 photometric method was lower than the number-based ambient aerosol penetration values. Number-based monodisperse NaCl aerosol penetration measurements showed that the most penetrating particle size was in the 50 nm range for all respirator models tested, with the exception of one model at ~200 nm size. Respirator models containing electrostatic filter media also showed lower penetration values with the TSI 8130 photometric method than the number-based penetration obtained for the most penetrating monodisperse particles. Results suggest that to provide a more challenging respirator filter test method than what is currently used for respirators containing electrostatic media, the test method should utilize a sufficient number of particles <100 nm and a count (particle number)-based detector.     

Evaluation of the performance of the N95-companion: effects of filter penetration and comparison with other aerosol instruments

Fit factor is the ratio of the particle concentration outside (C(out)) to the inside (C(in)) of the respirator and assumes that filter penetration is negligible. For Class-95 respirators, concerns were raised that filter penetration could bias fit test measurements. The TSI N95-Companion was designed to overcome this limitation by measuring only 40-60 nm size particles. Recent research has shown that particles in this size range are the most penetrating for respirators containing electrostic filter media. The goal of this study was to better understand the performance of the N95-Companion by assessing the impact of filter penetration and by comparing C(out)/C(in) ratios measured by other aerosol instruments (nano-Differential Mobility Analyzer/Ultrafine Condensation Particle Counter (nano-DMA/UCPC) and the TSI PortaCount Plus) using N95 filtering facepiece respirators sealed to a manikin and with intentionally created leaks. Results confirmed that 40-60 nm-diameter size room air particles were most penetrating for the respirators tested. A nonlinear relationship was found between the N95-Companion-measured C(out)/C(in) ratios and the other instruments at the sealed condition and at the small leak sizes because the N95-Companion measures only charged particles that are preferentially captured by the electrostic filter media, while the other instrument configurations also measure uncharged particles, which are captured less efficiently. The C(out)/C(in) ratios from the N95-Companion for experiments conducted under sealed condition suggest that filter penetration of negatively charged 40-60 nm size particles was less than 0.05%. Thus, the N95-Companion measured C(out)/C(in) ratios are due primarily to particle penetration through leakage, not through filter media, while the C(out)/C(in) ratios for the PortaCount, nano-DMA/UCPC, and UCPC result from a combination of face seal leakage and filter penetration.     

Characterizing inward leakage in a pressure-demand, self-contained breathing apparatus

An analytical model of the flow across a resistive flow path such as an orifice or pipe was applied to predict the inward leakage in the facepiece of a self-contained breathing apparatus (SCBA) during a steady below-ambient facepiece pressure. The model was used to estimate leakage rates with respect to the size of the leak and for below-ambient (negative) pressure conditions reflective of measured occurrences. Results of the model were also used to make quantitative estimates of the protection level of the respirator. Experiments were designed to induce a continuous below-ambient pressure inside the facepiece of a pressure-demand SCBA mounted on a headform. Negative facepiece pressure measured in the presence of a leak correlated with the measured particle concentration ratio. Results show that the analytical model generated reasonable estimates of leakage rates during conditions of negative pressure inside the facepiece. Thus, the analytical model performed well for constant flow conditions, demonstrating the capability to predict a momentary compromise in respirator protection during momentary negative facepiece pressure conditions.     

Advanced testing method to evaluate the performance of respirator filter media

Filter media for respirator applications are typically exposed to the cyclic flow condition, which is different from the constant flow condition adopted in filter testing standards. To understand the real performance of respirator filter media in the field it is required to investigate the penetration of particles through respirator filters under cyclic flow conditions representing breathing flow patterns of human beings. This article reports a new testing method for studying the individual effect of breathing frequency (BF) and peak inhalation flow rate (PIFR) on the particle penetration through respirator filter media. The new method includes the use of DMA (Differential Mobility Analyzer)-classified particles having the most penetrating particle size, MPPS (at the constant flowrate of equivalent mean inhalation flow rate, MIFR) as test aerosol. Two condensation particle counters (CPCs) are applied to measure the particle concentrations at the upstream and downstream of test filter media at the same time. Given the 10 Hz sampling time of CPCs, close-to-instantaneous particle penetration could be measured. A pilot study was performed to demonstrate the new testing method. It is found that the effect of BF on the particle penetration of test respirator filter media is of importance at all the tested peak inhalation flow rates (PIFRs), which is different from those reported in the previous work.     

Manikin-based performance evaluation of N95 filtering-facepiece respirators challenged with nanoparticles

Protection of the human respiratory system from exposure to nanoparticles is becoming an emerging issue in occupational hygiene. The potential adverse health effects associated with particles of approximately 1-100 nm are probably greater than submicron or micron-sized particles. The performance of two models of N95 half-facepiece-filtering respirators against nano-sized particles was evaluated at two inhalation flow rates, 30 and 85 l min(-1), following a manikin-based protocol. The aerosol concentration was measured outside and inside the facepiece using the Wide-Range Particle Spectrometer. Sodium chloride particles, conventionally used to certify N-series respirators under NIOSH 42 CFR 84 regulations, were utilized as the challenge aerosol. The targeted particle sizes ranged from 10 to 600 nm, although the standard certification tests are performed with particles of approximately 300 nm, which is assumed to be the most penetrating size. The results indicate that the nanoparticle penetration through a face-sealed N95 respirator may be in excess of the 5% threshold, particularly at high respiratory flow rates. Thus, N95 respirators may not always provide the expected respiratory protection for workers. The highest penetration values representing the poorest respirator protection conditions were observed in the particle diameter range of approximately 30-70 nm. Based on the theoretical simulation, we have concluded that for respirators utilizing mechanical filters, the peak penetration indeed occurs at the particle diameter of approximately 300 nm; however, for pre-charged fiber filters, which are commonly used for N95 respirators, the peak shifts toward nano-sizes. This study has confirmed that the neutralization of particles is a crucial element in evaluating the efficiency of a respirator. The variability of the respirator's performance was determined for both models and both flow rates. The analysis revealed that the coefficient of variation of the penetration ranged from 0.10 to 0.54 for particles of 20-100 nm in diameter. The fraction of N95 respirators for which the performance test at 85 l min(-1) demonstrated excessive (>5%) penetration of nanoparticles was as high as 9/10. The test results obtained in a relatively small (0.096 m(3)) test chamber and in a large (24.3 m(3)) walk-in chamber were found essentially the same, thus, suggesting that laboratory-based evaluations have a good potential to adequately represent the respirator field performance.