DIY Mask brace / fitter using twisted copper wire cores by FullPlasticScientist

Last crawled date: 3 years ago

This is a quick remix listing of the twin and earth DIY 6242Y cable mask brace concept.
This concept is to show that a mask brace can be constructed, so long as there are solid core copper wires available with an area of 2.5mm (approx. 1.78mm diameter) or above. Instead of one specific cable type.
It is constructed by twisting together 3 or more solid copper cores using a vice and drill. Using the same technique that electricians make twisted pair wires for EMF signal noise cancellation.
Bare copper wire of this thickness is hard to find, but is often used in large industrials transformers, generators and motors. Hence it should be more widely available globally than the British 6242Y mains cable type. It was used in this example as proof of concept.
Copper is naturally slowly anti--microbial over a period of hours. But only if it is not tarnished or lacquered. Transformer and motor wire is often lacquered. If so, it can still be used but the mask brace wire surfaces will not be anti-microbial.
To keep its anti-microbial properties, it must be polished daily so that it keeps its shine. If the copper surface becomes dull, which can occur after contact with human sweat, then it will lose its anti-microbial properties. See article below.https://www.sciencedaily.com/releases/2014/06/140617210344.htm
This concept is presented as a good faith effort to help with global pandemic efforts and should be considered as a last resort option only. It should not be used in place of already available and accredited PPE in accordance with local guidelines and regulations.
DOWNSIDES OF THIS CONCEPT
Significantly less comfortable than commercial, printed or 6242Y PVC mask brace variants.
The lower amount of contact area with the surgical mask means it is significantly more difficult to eliminate 100% of the leaks around the edges.
The wire ends are sharp and risk scratching or cutting the wearer’s face. Therefore, it is imperative that when constructing and forming to individual faces that THE WIRE ENDS ARE FOLDED BACK ON THE SIDES, AWAY FROM THE SKIN AND WRAPPED IN SEVERAL LAYERS OF THICK TAPE. If you construct and use this type of brace without bending the ends away from the face, there could be a significant risk of injury. Only use this concept with due caution, knowing the above risk of injury. Anyone given this type of mask brace concept must be made aware of this.
MATERIALS REQUIRED
3x 2.5mm area (approx. 1.78mm diameter) or thicker solid copper wire cores, stripped of their sheaths.
4x 200mm 'trash can' elastic bands
2x zip ties
Thick electrical insulation tape.
TOOLS REQUIRED
Pliers, to help form.
Electrical side cutters, to cut zip ties flush and prevent a sharp plastic burr.
Strong bench vice
Powerful hand drill, capable of slow rotation speed and high torque.
Scissors, to cut the tape.
Diamond file or similar, to deburr sharp ends of copper wire cores.
INSTRUCTIONS
Source 3 or more solid copper wires of 2.5mm area (1.78mm diameter) or thicker.
Straighten out and place side by side. Ensure they are not tangled, Lay out parallel to each other.
Clamp one end of the 3 copper wires firmly into a suitable vice.
Clamp the other end firmly into a powerful hand drill.
Ensure the vice cannot move, then slowly rotate the drill, this will twist the copper wire cores together as shown.
Once maximum twist has been achieved (twisted together without warping, should remain straight), stop the drill.
Cut the ends so that all copper strands end at the same position at either end.
File the ends of the copper wires with a diamond file to remove any sharp edges, must be as dull as possible to reduce risk of injury.
When bending over the ends of the twisted wire assembly, bend away from the direction that will be in contact with the skin to minimise risk of injury.
Wrap the bent over ends in thick and durable tape several times. More layers the better. To reduce risk of injury.
Form the newly twisted wire assembly using the same technique as the 6242Y PVC mask brace. See badge mask fitter video instructions for techniques to ensure it is correctly formed to your nose and cheeks.
Badger seal mask fitter concept.
https://making.engr.wisc.edu/mask-fitter/https://www.youtube.com/watch?v=0CSZrCUAm3g
Fit an ear saver to the mask to be worn, so that it is pulled taut to the face before the brace is fitted. This will significantly improve the chances of achieving a good fit.
Perform a user mask fit / seal checkhttps://www.cdc.gov/niosh/docs/2018-130/pdfs/2018-130.pdf
Wherever leaks are found around the edge of the mask, gently reform the twisted wire assembly by hand in order to improve its fit to the specific contours of your face. Repeat this process until no leakage is present and glasses do not fog up.
The commercial offerings from fix the mask and badger mask fitter are far better than this DIY stopgap solution. If you have access to an accredited commercial offering, that should be your first choice. This concept is intended to provide yet another alternative for those who cannot access appropriate certified commercial solutions where the pandemic still rages globally.
Disclaimer
This concept presented as a good faith effort to help with global pandemic efforts and should be considered as a last resort option only. It should not be used in place of already available and accredited PPE in accordance with local guidelines and regulations.
The author cannot provide any guarantees as to this concept’s ability to improve mask fit and hence protection factor of a surgical mask. It will be highly dependent on the skill of the person constructing it, and their ability to form it to the contours of a specific face. They should not be provided to others without significant instruction on how to form and perform a seal check. With due warning regarding risk of injury from frayed wire ends. Hence, it is an individual specific solution and not something that should be sold commercially on mass. It is a stop gap concept only for use when there are no other accredited PPE options available. It is untested and not verified by certified laboratories. Use at your own risk.