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gas mask

 
Dictionary: gas mask

n.
A respirator that contains a chemical air filter and is worn over the face as protection against toxic gases and aerosols.


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How Products are Made: How is a gas mask made?
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Background

A gas mask is a device designed to protect the wearer from noxious vapors, dust, and other pollutants. Masks may be designed to carry their own internal supply of fresh air, or they may be outfitted with a filter to screen out harmful contaminants. The latter type, known as an Air Purifying Respirator (APR), consists of a tight-fitting face piece that contains one or more filter cartridges, an exhalation valve, and transparent eye pieces. The first APR was patented in 1914 by Garret Morgan of Cleveland, Ohio, an African American inventor also credited with major improvements in the traffic signal. When the Cleveland Waterworks exploded in 1916, Morgan showed the value of his invention by entering the gas-filled tunnel under Lake Erie to rescue workers. Morgan's device later evolved into the gas mask, used in World War I to protect soldiers against chemicals used in warfare.

Since that early time, there have been significant advances in gas mask technology, particularly in the area of new filtration aids. In addition, masks have been made more comfortable and tighter fitting with modern plastics and silicone rubber compounds. Today APRs are used to filter many undesirable airborne substances, including toxic industrial fumes, vaporized paint, particulate pollution, and some gases used in chemical warfare. These masks are produced in several styles, some that cover only the mouth and nose and others that cover the entire face, including the eyes. They may be designed for military as well as industrial use but, even though the two types are similar in design, the military masks must meet different standards than those used in industry. This article will focus on manufacture of the full face type of mask used for industrial applications.

Raw Materials

A full-face gas mask consists of a filter cartridge, flexible face covering piece, transparent eye lenses, and a series of straps and bands to hold the device snugly in place. The filter cartridge is a plastic canister 3-4 inches (8-10 cm) across and 1 inch (2.5 cm) deep, which contains a filtration aid. Carbon based filtrants are commonly used because they can adsorb large quantities of organic gases, especially high molecular weight vapors like those used in chemical warfare. However, inorganic vapors are not usually strongly adsorbed on carbon. The adsorptive properties of carbon can be enhanced by impregnating the particles with specific reactants or decomposition catalysts. Such chemically treated carbon is known as "activated carbon." The type of activated carbon employed in a given filter cartridge depends on the specific type of industrial contaminant to be screened. For example, carbon treated with a combination of chromium and copper, known as "Whetlerite carbon," has been used since the 1940s to screen out hydrogen cyanide, cyanogen chloride, and formaldehyde. Today, due to concerns about chromium toxicity, a combination of molybdenum and triethylenediamine is used instead. Other types of activated carbon employ silver or oxides of iron and zinc to trap contaminants. Sodium-, potassium- and alkali-treated carbon are used to absorb sewage vapors (hydrogen sulfide), chlorine, and other harmful gases.

The "skirt," or face-covering piece, of the mask is used to hold the other components in place and to provide a secure seal around the face area. Depending upon mask design, an exhalation valve may be inserted in the face piece. This one-way valve allows exhaust gases to be expelled without allowing outside air into the mask.

The eyepieces used in gas masks are chemically resistant, clear plastic lenses. Their main function is to ensure the wearer's vision is not compromised. Depending on the industrial environment in which the mask is to be used, the eyepieces may have to be specially treated to be shatterproof, fog resistant, or to screen out certain types of light. Most gas mask manufacturers do not make their own eyepieces; instead they are molded from polycarbonate plastic by an outside supplier and shipped to the manufacturers for assembly.

The elastic straps that hold the mask on the face are typically made of silicone rubber. Supplementary straps may be added to allow the mask to be comfortably hung around the neck during breaks in work.

Design

The design of the mask itself varies by the industrial application. Some masks are designed with speech diaphragms, some are built to accept extra filters, and others are made to be connected to an extenal air supply. Although the fundamental design does not vary for a given type of mask, the kind of filtrant used will vary depending on the product's intended use. Manufacturers stock a variety of mask styles and cartridge filtrants. When they receive orders for a specific type of mask, they can custom design a mask that has the appropriate features.

The Manufacturing
Process

  1. The canister is made from styrene plastic, which is resistant to water and other chemicals, has good dimensional stability, and is specially designed for injection molding. Injection molding is a process by which molten plastic is injected into a mold under high pressure. The mold used for gas mask canisters consists of two disk-shaped pieces of metal that are clamped together. The plastic resin is liquefied by heating and then injected into the mold via an injection plunger. The mold is then subjected to high pressure. Most injection machines compress the mold with a pressure ranging from 50-2,500 tons (51-2,540 metric tons). After the molten plastic has been compressed, cooling water is forced through channels in the mold to cool and harden the plastic. The pressure is released, the two halves of the mold are separated, and the finished canister is ejected.

    Styrene is a thermoplastic resin, which means it can be repeatedly remelted, so the scrap pieces can be reworked to make additional canisters. Therefore, there is very little wasted plastic in this process. A similar molding process is conducted to create small circular screens that fit inside the canister. The screens are designed to hold the activated carbon in place inside the cartridge. As the canisters travel down the assembly line, one screen is inserted, the canister is filled with the appropriate filtrant, then the second screen is put into place.

  2. The face piece is injection molded from silicone rubber. Silicone rubber has outstanding stability, is resistant to high temperatures, and can conform to curves in the face and head. It is also thermoplastic and can remolded as necessary. The molding process is very similar to the one described above. After molding the skirt must be removed from the mold, and any rough edges must be cleaned off by hand before the other components can be attached.
  3. The pieces are assembled on a partially automated assembly line with two to four line workers supervising the process. The completed filter canister is attached to the face piece and the eyepieces are inserted and held in place with adhesive. Finally the straps and bands are attached to the face piece with metal rivets. When assembly is complete, the mask is given a final quality check. When the masks pass inspection, they are identified with the appropriate markings in accordance with the American National Standard for Identification of Air Purifying Respirator Cartridges and Canisters. The finished masks are packaged for shipping. The containers used to package the masks must also designate the identity of the mask. Furthermore, they must be designed for easy access if the masks might be used in the event of an emergency.

Byproducts/Waste

Depending on the type of chemical treatment the activated carbon has been exposed to, it may be classified as chemical waste. This is the case with some filtrants, such as chromium-treated carbon. The injection molding process used for the canisters and the face pieces generates little waste since any lost resin can be remelted and used again. The lenses are manufactured by an outside vendor, so gas mask manufacturers do not have to address the issue of waste polycarbonate.

Quality Control

Gas masks, and air purifying respirators in general, are regulated by the Code of Federal Regulations (CFR). These regulations specify the type of masks to use for a specific application. Examples of the different mask types recognized by the CFR include self-contained breathing apparatus, non-powered air purifying particulate respirators, chemical cartridge respirators, and dust masks. The regulations stipulate the exact kind of testing that must be done to ensure the quality of the finished product. The type of testing depends on the masks' final application, that is, what kind of contaminants it will be expected to filter. The CFR specifies the types of contaminants that the gas must be tested with, and it also stipulates the conditions under which the testing must be conducted. For example, some masks must be exposed to the contaminant for long periods of time. Others must be tested under specific temperature and humidity conditions. This is done by drawing an air stream contaminated with a known amount of poison through the mask. The amount of time required for the contaminant to saturate the filter and begin to pass through is then measured.

Testing is done at several points in the manufacturing process. There is an initial inspection of incoming goods to ensure they meet minimum quality specifications. This includes the filtrants, the resins used for molding, and the finished eyepieces as they are received. The canister must be tested after assembly to ensure it has proper seal and that the carbon filter works. The mask is tested once again after all componentry has been assembled. The final mask may be placed on a mannequin head to ensure that the seal is tight and that the mask maintains its seal in movement.

The Future

Over the last 80 years, the basic technology of gas masks has been tested repeatedly, and so is not likely to change in the future. The challenge for the APR industry will be to develop products for special purposes, such as infant respirators or masks for persons with head wounds and other disabling injuries. The future of these products also relies on advances in the material sciences, which allows production of smaller, more lightweight products. In fact, current research efforts in carbon chemistry are anticipated to result in the development of a filter canister that is only half the size of the current standard and is more effective. These and other improvements in materials will result in new generations of respirator devices for industrial use, as well as for medical and military applications.

Where to Learn More

Books

Ahmstead, B.H. Manufacturing Processes. John Wiley and Sons, 1977.

Other

Laboratory for National Testing of Gas Masks. http://www.niih.go.jp:80/guide/english/profile/gasmask/gasmask.htm (July 9, 1997).

[Article by: Randy Schueller]


A protective mask used to cover a person's face as a defense against poisonous gas.

See the Introduction, Abbreviations and Pronunciation for further details.

 
Columbia Encyclopedia: gas mask
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gas mask, face covering or device used to protect the wearer from injurious gases and other noxious materials by filtering and purifying inhaled air. In addition to military use (see chemical warfare), gas masks are employed in mining, in industrial chemistry, and by firemen and rescue squads. The gas mask consists essentially of a face cover with two eyepieces and a mouthpiece that communicates with a canister containing a filter. The filter absorbs noxious gases as they pass through the canister to the mouth. The face cover also has a one-way outlet valve for exhaled air. See poison gas.


Wikipedia: Gas mask
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Contents

For "a mask for inhaling gas through", see Mask#Functional masks.

A gas mask is a mask worn over the face to protect the wearer from inhaling "airborne pollutants" and toxic gases. The mask forms a sealed cover over the nose and mouth, but may also cover the eyes and other vulnerable soft tissues of the face. Some gas masks are also respirators, though the word gas mask is often used to refer to military equipment (e.g. Field Protective Mask, etc.) (The user of the gas mask is not protected from gas that the skin can absorb.)

Airborne toxic materials may be gaseous (for example the chlorine gas used in World War I) or particulate (such as many biological agents developed for weapons such as bacteria, viruses and toxins). Many gas masks include protection from both types. During riots where tear gas or CS-gas is employed by riot police, gas masks are commonly used by police and rioters alike.

Aside from serving their functional purposes, gas masks are also used as emblems in Industrial music, and by graffiti taggers because the mask protects them from the graffiti canister's toxic fumes. Also closely related is the eroticization of gas masks as a sexual fetish.

The traditional gas mask style with two small circular eye windows originated when the only suitable material for these eye windows was glass or perspex; as glass is notoriously brittle, glass eye windows had to be kept small and thick. Later, discovery of polycarbonate allowed gas masks with a big fullface window, as in the image at this link.

Some have one or two filters attached to the face piece: image.

Some have a large filter connected to the face piece by a hose: image.

Safety of old gas masks

Gas masks have a limited useful lifespan that is related to the absorbent capacity of the filter. Once the filter has been saturated with hazardous chemicals, it ceases to provide protection and the user may be injured. Most gas masks use sealing caps over the air intake to prevent the filter from degrading before use, but the protective abilities also degrade as the filter ages or if it is exposed to moisture and heat. Very old unused gas mask filters from World War II may not be effective at all in protecting the user, and can potentially cause harm to the user due to long-term changes in the filter chemical composition.

It is important to note at the outset that World War II gas masks contained blue asbestos in their filters, and this material continued to be used until at least 1956. Breathing blue asbestos in the factories resulted in death from mesothelioma of 10% of workers, and between 2.5 and 3.2 times the normal incidence of lung or respiratory cancers[1]. Current advice is never to wear any gas mask of uncertain military origin.

Modern gas masks are quite safe and do not use asbestos, but it is still important to be careful when using a modern gas mask. Typically masks using 40mm connections are more recent design. Rubber also degrades with time so new in box "Modern type" masks can be cracked and leak.

Principles of construction

Absorption is the process of being drawn into a (usually larger) body, or substrate, and adsorption is the process of deposition upon a surface. This can be used to remove both particulate and gaseous hazards. Although some form of reaction may take place, it is not necessary; the method may work by attractive charges, for example, if the target particles are positively charged, use a negatively charged substrate. Examples of substrates include activated carbon, and zeolites. This effect can be very simple and highly effective, for example using a damp cloth to cover the mouth and nose whilst escaping a fire. While this method can be effective at trapping particulates produced by combustion, it does not filter out harmful gases which may be toxic or which displace the oxygen required for survival.

Reaction and exchange

This principle relies upon the fact that substances that can do harm to humans are usually more reactive than air. This method of separation will use some form of generally reactive substance (for example an acid) coating or supported by some solid material. An example is resins. These can be created with different groups of atoms (usually called functional groups) that exhibit different properties. Thus a resin can be tailored to a particular toxic group. When the reactive substance comes in contact with the resin, it will bond to it, removing it from the air stream. It may also exchange with a less harmful substance at this site.

Though it was crude, the hypo helmet was a stopgap measure for British troops in the trenches that offered at least some protection during a gas attack. As the months passed and the use of poison gas occurred more frequently, more sophisticated masks were developed and introduced. There are two main difficulties with gas mask design:

  • The user may be exposed to many different types of toxic material. Military personnel are especially prone to being exposed to a diverse range of toxic gases. However if the mask is for a particular use (such as the protection from a specific toxic material in a factory), then the design can be much simpler and the cost lower.
  • The protection will wear off over time. Filters will clog up, substrates for absorption will fill up, and reactive filters will run out of reactive substance. This means that the user only has protection for a limited time, and then they must either replace the filter device in the mask, or use a new mask.

History and development of the gas mask

An early type of rudimentary gas mask was invented in the 9th century by the Banu Musa brothers in Baghdad, Iraq. They described it in their Book of Ingenious Devices,[2] mainly for protecting workers in polluted wells.[3]

Primitive respirator examples were used by miners and introduced by Alexander von Humboldt already in 1799, when he worked as a mining engineer in Prussia, as well as a Plague Doctor's bird beak shaped mask/face piece.

The gas mask was patented on June 12, 1849, by the American, Lewis Haslett, in Louisville, Kentucky. It was an "Inhaler or Lung Protector," issued for an air purifying respirator. Haslett's device filtered dust from the air.[4]

Early versions were constructed by the Scottish chemist John Stenhouse in 1854 and the physicist John Tyndall in the 1870s.

One such design began as a "Safety Hood and Smoke Protector" invented by African American inventor, Garrett A. Morgan in 1912, and patented in 1914. It was a simple device, consisting of a cotton hood with two hoses which hung down to the floor, allowing the wearer to breathe the safer air found there. In addition, moist sponges were inserted at the end of the hoses in order to better filter the air. Morgan won acclaim for his device when in 1916 he, his brother, and two other volunteers used his device to rescue numerous men from the gas and smoke-filled tunnels beneath Lake Erie in the Cleveland Waterworks.

The first use of poison gas on the Western Front was on 22 April 1915, by the Germans at Ypres, against Canadian and French colonial troops. The initial response was to equip troops with cotton mouth pads for protection. Soon afterwards the British added a long cloth which was used to tie chemical-soaked mouth pads into place, and which was called the Black Veil Respirator. Dr. Cluny MacPherson of The Royal Newfoundland Regiment brought the idea of a mask made of chemical absorbing fabric and which fitted over the entire head to England,[5] and this was developed into the British Hypo Helmet of June 1915. This primitive type of mask went through several stages of development before being superseded in 1916 by the canister gas mask of 1916.[6] This had a mask connected to a tin can containing the absorbent materials by a hose.

In 1915, American chemist and inventor credited with the invention of the gas mask [7] James Bert Garner read a newspaper article describing a gas attack on British forces which he hypothesized had employed chlorine gas. Remembering experiments he had performed while teaching at the University of Chicago, he set about creating the first gas mask which he tested on two of his associates in a gas filled chamber. Following the successful completion of the test, he provided the results to the British government.[8]
Garner's mask was the first to be used on the Western front during World War I.[9] Also in World War I, since dogs were frequently used on the front lines, a special type of gas mask was developed that dogs were trained to wear.[10]

The British Royal Society of Chemistry claims that British scientist Edward Harrison developed the first practical gas mask for mass production, a claim supported by a thank-you note written by Winston Churchill.[11]

In America thousands of gas masks were produced for American as well as Allied troops. Mine Safety Appliances was a chief producer. This mask was later used widely in industry.[8]

Gas masks development since has mirrored the development of chemical agents in warfare, filling the need to protect against ever more deadly threats, biological weapons, and radioactive dust in the nuclear era. However, where agents that cause harm through contact or penetration of the skin occurs, such as blister agent or nerve agent, a gas mask alone is not sufficient protection, and full protective clothing must be worn in addition, to protect from contact with the atmosphere. For reasons of civil defense and personal protection, individuals often purchase gas masks in the belief that they protect against the harmful effects of an attack with nuclear, biological, or chemical (NBC) agents; which is only partially true, as gas masks protect only against respiratory absorption. Whilst most military gas masks are designed to be capable of protection against spectrum of NBC agents, they can be coupled with filter canisters that are proof against those agents (heavier) or just against riot control agents and smoke (lighter, and often used for training purposes); likewise there are lightweight masks solely for use in riot control agents and not for NBC situations.

Although thorough training and the availability of gas masks and other protective equipment can render the casualty-causing effects of an attack by chemical agents nullified, troops who are forced to operate in full protective gear are less efficient in completing their given tasks, tire easily, and may be affected psychologically by the threat of attack by these weapons. During the Cold War era, it was seen as inevitable that there would be a constant NBC threat on the battlefield, and thus troops needed protection in which they could remain fully functional; thus protective gear, and especially gas masks have evolved to incorporate innovations in terms of increasing user-comfort, and in compatibility with other equipment (from drinking devices to artificial respiration tubes, to communications systems etc). The gas mask has thus now arrived at a 'fourth generation' of development.

History of Absorbents and Neutralizers

Activated charcoal is a common component of gas masks. It is a carbon with an extremely high surface area and which attracts all manner of pollutants from air and water. Pollutants do not react with the carbon but are bonded to it in a process called adsorption. Over time the activated carbon becomes thoroughly coated and it ceases to remove pollutants. However, the charcoal can be reactivated and restored to its original state by baking the charcoal with high heat, which either evaporates or burns off the pollutants.

In the first gas masks of World War I, it was initially found that wood charcoal was a good adsorbent of poison gases. In about 1918 it was found that charcoals made from the shells and seeds of various fruits and nuts such as coconuts, chestnuts, horse-chestnuts, and peach stones performed much better than wood charcoal. These waste materials were collected from the public in recycling programs to assist the war effort.[12]

See also

References

  1. ^ (British Medical Journal 19 September 2006 oem.bmj.com/cgi/reprint/39/4/344.pdf)
  2. ^ Donald Routledge Hill, "Mechanical Engineering in the Medieval Near East", Scientific American, May 1991, p. 64-69. (cf. Donald Routledge Hill, Mechanical Engineering)
  3. ^ Young, M. J. L. (1990), The Cambridge history of Arabic literature, Cambridge University Press, p. 264, ISBN 0521327636 
  4. ^ "Gas Masks - History". Mary Bellis. http://inventors.about.com/od/gstartinventions/a/gasmask.htm. Retrieved 2008-06-12. 
  5. ^ Victor Lefebure (1923). The Riddle of the Rhine: Chemical Strategy in Peace and War. The Chemical Foundation Inc.. http://www.gutenberg.org/dirs/etext98/rrhin10.txt. 
  6. ^ "The UK". The Gas Mask Database. http://www.gasmasks.net/database/uk/uk.htm. 
  7. ^ Who Was Who in America, Vol. V, 1969-1973
  8. ^ a b Pittsburgh Post-Gazette, November 30th, 1960
  9. ^ PG-13.eps
  10. ^ Gas-Masks for Dogs / Dumb Heroes of the Fighting Front, Popular Science monthly, December 1918, page 75, Scanned by Google Books: http://books.google.com/books?id=EikDAAAAMBAJ&pg=PA75
  11. ^ "Gas mask inventor Harrison honoured in death by Churchill". Royal Society of Chemistry. http://www.rsc.org/AboutUs/News/PressReleases/2008/HarrisonLetter.asp. Retrieved 2008-06-12. 
  12. ^ Once Worthless Things that have Suddenly Become of Value, Popular Science monthly, December 1918, page 80, Scanned by Google Books: http://books.google.com/books?id=EikDAAAAMBAJ&pg=PA80

External links


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