One day welders everywhere will be able to breathe a little easier, thanks to Steve Charles.
The 40-year-old Oxford resident has invented a welding helmet with a built-in respirator that’s economical, comfortable and most importantly, safe.
‘This gives (welders) another option as far as keeping their lungs safe,? said Charles, who’s been an engineer for 22 years and is currently employed as a product engineer for the Troy-based Tur-Tech, Inc.
Basically, Charles ‘got the old Dremel tool out? and ‘blasted a few holes in the sides? of a standard $30 welding helmet made by the Missouri-based Jackson Products.
Using a special fastening system he designed and built inside the helmet, Charles installed a $30 respirator made by AOSafety with filters specifically designed to trap the toxic fumes generated by welding, allowing the wearer to breathe clean air.
Common welding processes produce many airborne contaminants, which may include fluorides, carbon monoxide, nitrogen dioxide, nitric oxide, ozone, and metal fumes. Metal fumes are very small particles that are formed when hot vapors cool and condense into very small particles. The particles are often smaller than 1/50th the width of a human hair.
As a result, welders are at-risk to develop respiratory problems, lung damage, metal fume fever, cancer, kidney and heart damage, gastrointestinal illnesses and reproductive problems.
To protect welders from these harmful fumes, the air filters in Charles? invention protrude from two holes in the left and right sides of the helmet near the wearer’s mouth.
‘It works great,? said Charles, noting he showed it to some welders who tried it out and immediately asked, ‘When are you gonna make them??
Charles applied for a ‘utility patent? in June and received patent-pending status in August. The entire patent process can take up to 18 months from the date it’s applied for.
Charles said he chose to apply for a utility patent as opposed to a ‘design patent? because the former lasts 20 years and ‘makes it harder for people to infringe on the design.?
A design patent lasts 14 years and can be easily infringed on with only minor modifications to an invention, for example, changing the shape of the mask’s filter holes from circles to ovals.
The idea for the welding helmet/respirator came from an August 2004 conversation with friend Greg Pilibosian, a manager for Engineered Heat Treat, Inc. in Madison Heights.
Tilibosian was complaining about how expensive air tanks that force feed oxygen into welding helmets are (about $1,000 each), how they’re not necessary for many welding jobs and how cumbersome they can be for the wearer.
Charles? invention appears to solve these problems.
He estimated his welding helmet would probably sell for about $100 and when it comes time to replace the respirator cartridges, the cost is about $15 for a set. ‘I’m just trying to make it more economical for people,? Charles said.
Normally, most welding jobs take place in ventilated shops with ‘ample room,? according to Charles, which is the ideal environment for respirators which work by drawing in air and feeding it out. Costly air tanks are not necessary in these situations.
Finally, together Charles? helmet and respirator weigh ‘less than two pounds,? which means it’s light, comfortable and easy to maneuver in.
Charles said he’s talked with a product engineer from Jackson Products about his invention, but has yet to set up a meeting with the company about possibly manufacturing it.
‘They say it’s a great idea,? he said.
Charles said he is completely open to talking with other companies about producing and marketing his invention.
But he’s also considering doing it himself and marketing the product under the name ‘SAF-T-MET.?
Anyone who’s interested in manufacturing and marketing Charles? invention can e-mail him at zz6pxl@aol.com.