A unique solution to retrofit a single interchangeable filter into two separate devices.
Two radioaerosol delivery devices, commonly used in pulmonary imaging studies for nuclear medicine applications require both a HEPA filtration device and a bacterial filtration device. The filters are essential to protect the patient from contamination and to safeguard the study environment from radioactive exhaled particulate. The client needed to cut costs, improve efficiency, and improve aesthetics to help brand their new device. AG Industries was contracted to deliver custom filter solutions that allowed for HEPA & Bacterial filtration in a universal housing.
AG Industries developed a unique filter housing using a single injection-molding tool with interchangeable inserts, sonic welding and interchangeable filter membranes. Extensive prototyping, testing, and modeling were done upfront to create an intricate tool design so that each of the three versions of the filter can be manufactured quickly and efficiently with a simple tool insert change.
The customer’s goals for an interchangeable device with a universal look for each of their mechanisms were met as well as the need to complete the project with low capital investment.
UNIVERSAL OXYGEN FILTER
An adaptable filter system for use across three iterations of oxygen concentrators.
Three iterations of the most popular brand of Oxygen Concentrator had been introduced over the course of 15 years, each with the same filter footprint, but different connection methods, air flow requirements, and sound attenuation needs.
AG Industries was challenged to create a single universal design for use in all three iterations of this popular unit. This design would combine a female thread connection, high airflow, with low sound attenuation; 22mm male connection, low airflow, with high sound attenuation; and 22mm male connection, medium airflow, with High sound attenuation.
AG Industries created a universal filter by designing a method for male and female connections to be used on a single shot. To regulate the airflow and give end users the flexibility to tune the filter to their specific unit, AG developed a patented Air Dial Inlet feature. This allows the air dial to be easily adjusted to the appropriate level of inlet flow. These two solutions not only combined all three filter needs in a durable and customizable way, but cut down on mold changes, inserts and parts.
The customer can now stock just one universal filter to cut down inventory levels and issues with stock matching.
LONG LIFE COMPRESSOR FILTER
A durable filter muffler that provides years of HEPA filtration without adhesives.
Because compressor filters operate in harsh conditions such as: temperature fluctuations and constant vibration, AG Industries’ client needed a HEPA filter with a brass female thread that would provide 5 years of consistent performance & durability in the closed compressor environment.
AG Industries determined the best solution would be a specialized filter/muffler device designed to protect the patient and compressor from contamination. Research determined a durable, high-temp Valox® Plastic with very stable characteristics was the best material for the job. Using proprietary thermal welding techniques AG Industries built a three-part filter housing system to encapsulate a modified synthetic HEPA pleat pack without using sealant.
Using a multi-step approach and these techniques, the filter material, brass thread, and filter seals are airtight, secure, and able to withstand the stress of large temperature fluctuations and the constant vibratory conditions. Additionally, the filter serves as a muffler to regulate air intake into the compressor and reduce noise generated by the motor.
ERGONOMIC HOSE CUFF
A carefully designed lightweight hose cuff, vital to ensuring a pleasurable experience for all users.
Customer inquiries and market research indicated a need for an innovative update to the design of CPAP tubing hose cuffs. During research, AG Industries found that users had two major issues with existing hose cuffs: the weight of the hose cuff at the interface and difficulty detaching from the connection port without damaging the hose or the port.
AG industries worked to engineer a cuff that would fit ergonomically in user’s hands and make attachment and detachment much easier. In addition to a slimmer shape, we used AG redesigned the entire cuff & tube interface to reduce the overall size and weight of the cuff.
Weight reduction greatly decreased the pull of the cuff at the interface, thereby giving the user a more comfortable feel to their mask. The design patented ergonomic shape of the hose cuff fit securely into user’s hands and firmly on the port, simplifying attachment and detachment and reducing the likelihood of a compromised mask seal as well. With less drag on the mask, patients will rest easier and increase compliance with their sleep therapy.