Breavid-19 the Disposable PAPR Hood

First version of our helmet.
Solid helmet solution if we had continued with hose option.
PAPR that inspires us.
Our blower fan is more than enough for our solution.
All the components will be entegrated to this helmet.
This polythelyn bag will be our disposable hood.
Motor and filter housing integrated to the helmet.

Inspiration

During COVID-19 pandemic we all are experiencing new ways of living. People must stay at home in order to prevent the spoilage of the virus. But at the same time, some people of the society like healthcare professionals, delivery staff and workers at shopping areas, drivers need to pursue to work as frontline workers. They need to wear personal protective equipment (PPE). But the currently available conventional PPEs like N95 masks have some difficulties whilst using. They are not suitable for all face types so they are not providing a perfect seal and not covering the full face. Moreover, they cause buries on face for long time usage. On the other hand, Powered Air Purifying Respirator Masks (PAPR) are relatively expensive, mostly cost over £250 if you can find it in stores.

PAPR is an enclosed air chamber around the face or entire head that provides clean breathing air via a fan-powered filtering unit. PAPR's are much more comfortable than a face mask and function properly without requiring a continuously perfect face seal. Fully enclosed PAPR's protect against aerosols and splash from all directions.

Maintaining a good seal with a mask often means more band tension. After several hours of usage, bruising or skin damage can occur with tight bands. PAPR's don't use a tight seal nor do they need high band tension.

Buries caused by masks

Our vision is to manufacture a low-cost, full-face/head covering PAPR hood, which will be easy to use and easily procurable for everyone.

Our key objective is to save front-liners and re-open all businesses by providing them a full face covering PAPR hood under £100.

Our main area of focus is to produce a full-face covering PAPR mask which will be available for everyone and can be produced with conventional and already available in-stock items.

Problems

FFP2/N95 face masks require perfect sealing and causes buries for prolonged usage
face masks are not providing a perfect fit for every face type
Don/Doff cycle needs special training, there are many cases because of this
Breathing is very difficult
Requires extra goggles (not disposable, requires decontamination)
Requires head/hair covering disposable caps
PAPRs hoods or masks requires decontamination

What it does

Eliminates face sealing need and buries by powered positive air pressure
Eliminate decontamination need by disposable hood and filter caps
Eliminate goggle and hair cover cap need
Simple and easy one person donning/doffing
Eliminates breathing difficulty

How I built it

In this project, we will prototype simple and low-cost full face/head covering PAPR (Powered Air Purifying Respirator) Hood, it protects both aerosol, droplet, and splash threat from all directions. It will isolate people via positive pressure instead of requiring a perfect face to mask seal.

The hood is going to be made out of transparent material over the head and be secured around the neck. The breathable environment will be at positive pressure. Expiration will be a unidirectional flow valve or additional output filters. Blower type fan will suck the air through N95/HEPA filter deliver into the hood. Battery block is a standard power bank with its own switch. Hood will fit with a comfortable, yet effective seal around the neck with a personal utility strap. We used a safety helmet for mounting the components on it. A blower, battery, 3d printed adaptor for filter/blower connection and polythene bag as hood are used.

Expected impacts on society. the economy and the environment:

Powered Positive Pressured Air Respirators are above £250 level in the market, hence it is not reachable by the public. But our innovation will cost under £100.
People with facial hair cannot use N95 masks because of the sealing problems on the face, but our approach doesn't need sealing.
All frontline workers can use our masks, especially in markets, pharmacies, hospitals, post offices, etc. since they have to be open during the lockdown. So many stores can be re-opened with proper PAPR mask usage training.

Challenges I ran into

Finding N95 or N100 filter rolls is the most difficult part but HEPA filters produced for other purposes will be modified.

Accomplishments that I'm proud of

3D drawings have been completed and helmet, bags, filaments, blower and power source purchased and delivered to the team. We started the 3D printed prototype production. Blower and Filter related parts are 3D printed and they are functional now. Tested the cfm of blower and it meets the requirements. We have completed the working prototype. Can be watched here (https://youtu.be/k481iwZd1pc).

What I learned

The most expensive component is a battery that lasts more than 8 hours. We have difficulties to reach the end-user to explain our solution. We may need assistance communicating this idea to frontline workers We need financial and technical guidance to navigate the regulatory pathways to obtain CE Marking and FDA approval.

What's next for Breavid-19 PAPR Hood (Business Plan)

Get ready for pre-series production. 3D print and assemble the parts.
Test the CFM of blower after filter integration.
Decide on the battery pack type to extend operating life.
Testing filtration capability.
Pitch deck to investors and sending emails for marketing.
After getting the first orders, find an injection molding facility for 3D printed parts.