EP4292670A1 - Ffp2-type filter face masks with two layers - Google Patents
Ffp2-type filter face masks with two layers Download PDFInfo
- Publication number
- EP4292670A1 EP4292670A1 EP23178511.4A EP23178511A EP4292670A1 EP 4292670 A1 EP4292670 A1 EP 4292670A1 EP 23178511 A EP23178511 A EP 23178511A EP 4292670 A1 EP4292670 A1 EP 4292670A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- layers
- layer
- ffp2
- spunbond
- polypropylene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000004744 fabric Substances 0.000 claims abstract description 8
- 230000004927 fusion Effects 0.000 claims abstract description 6
- 239000004743 Polypropylene Substances 0.000 claims description 22
- 229920001155 polypropylene Polymers 0.000 claims description 22
- -1 polypropylene Polymers 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 10
- 238000005507 spraying Methods 0.000 claims 1
- 238000001914 filtration Methods 0.000 abstract description 12
- 239000004750 melt-blown nonwoven Substances 0.000 abstract description 4
- 238000002360 preparation method Methods 0.000 abstract description 2
- 239000004745 nonwoven fabric Substances 0.000 description 16
- 238000005516 engineering process Methods 0.000 description 8
- 229920001410 Microfiber Polymers 0.000 description 7
- 239000003658 microfiber Substances 0.000 description 7
- 238000009987 spinning Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000035515 penetration Effects 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 241000894006 Bacteria Species 0.000 description 1
- 241000700605 Viruses Species 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 210000003484 anatomy Anatomy 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 230000000241 respiratory effect Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B23/00—Filters for breathing-protection purposes
- A62B23/02—Filters for breathing-protection purposes for respirators
- A62B23/025—Filters for breathing-protection purposes for respirators the filter having substantially the shape of a mask
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
Definitions
- the subject of the present invention is the preparation of an FFP2NR-type mask made up solely of two layers of meltblown nonwoven fabric with high filtering power bonded through thermal fusion to a layer of spunbond fabric.
- FFP2-type face masks are able to filter up to 94% of particles suspended in the air equal to 0.6 ⁇ m in size. They provide effective protection against smoke, dust, aerosols, bacteria and viruses. Face masks with filtering capacity are obtained by using generally two different types of nonwoven fabric superimposed according to combinations that vary according to the type of mask. Spunbond nonwoven fabric has the main function of mechanical support and of comfort in contact with the skin of those who wear them, while meltblown nonwoven fabric, with a denser weave, guarantees filtering capacity and breathability. The main function, that is the filtering capacity, is therefore guaranteed above all by the meltblown layer.
- Meltblown nonwoven fabric is prepared through extrusion of the melted polymer, typically polypropylene, by means of a particular "blown spinning" technology. In this way long and very thin fibres are produced which are stretched and cooled by blowing warm air while the fibres are projected onto a collection support (a cylinder or another appropriate surface). In this way a strip of finely entangled microfibres is created which is collected into rolls and subsequently converted into finished products. The fibres produced in this way are extremely fine.
- the fibres of polypropylene (PP) are spun and then dispersed directly onto a baffle net by means of air jets.
- the spunbond technology allows high speeds and economical production costs.
- the PP microfibres are bonded by resins or thermally.
- Polypropylene (PP) spunbonds are produced with even higher speed and at decidedly lower temperatures with respect to nonwoven fabrics of different composition, exploiting the lower melting point.
- the spunbond technology allows nonwoven fabrics to be obtained that are characterised by microfibres of larger size with respect to the meltblown technology.
- the spunbond nonwoven fabrics are decidedly more robust.
- the larger microfibres of spunbond spinning do not confer high filtering capacity which is instead guaranteed by the meltdown nonwoven fabric.
- meltblown (M) is already bonded in production (or subsequently) with yarn generated with the spunbond technology (S).
- S spunbond technology
- the masks are typically constituted by the superimposing of at least three layers of nonwoven fabric with different functions and features: normally an external layer of hydrophobic spunbond (S) nonwoven fabric, with good mechanical strength, a filtering layer of meltblown (M) nonwoven fabric, made up of smaller microfibres (1-3 m), and an internal layer again of hydrophobic and biocompatible spunbond (S) nonwoven fabric intended to come into contact with the skin.
- S hydrophobic spunbond
- M meltblown
- S meltblown
- the object of the present invention is the manufacture of an ergonomic, lightweight and breathable face mask able to ensure the filtering performances provided by the EN149 standard in force.
- the solution proposed by the invention is advantageous and overcomes the disadvantages of the prior art connected to multilayer configurations rather than simply with two layers, not only maintaining the filtration efficacy of traditional masks but also improving it.
- FFP2-type face masks are made up of a material with two layers obtained by thermal fusion of a layer of meltblown polypropylene with grammage of 30-50g/m 2 on a layer of spunbond polypropylene nonwoven fabric with grammage of 30-50g/m 2 .
- the density of the material with two layers which makes up the mask of the invention is typically comprised between 0.90 and 0.96 kg/dm 3 .
- the thermal fusion of the layer of meltblown polypropylene on the layer of spunbond polypropylene nonwoven fabric takes place at a temperature of 150-200°C, preferably 160°C approximately.
- the spunbond polypropylene is a nonwoven fabric made up of continuous filaments in 100% polypropylene arranged randomly and welded thermally via a calendering process.
- the meltblown is made up of polypropylene microfibres with diameter 2 nm.
- the meltblown is characterised by the extrusion of the melted polymer by means of a particular technology of blown spinning.
- the mass of melted polymer is transformed into long and very thin fibres which are projected onto a collection support traversed by a cooling air flow. In this way a veil of finely entangled microfibres is created which is collected in reels and subsequently converted into finished products.
- Table 1 here below are the technical features - mechanical-dielectric-thermal - of the polypropylene used for the production of the masks.
- Table 1 PROPERTIES UNIT OF MEASUREMENT METHOD PP MECHANICAL SPECIFIC WEIGHT g/cm 3 ISO 1183 0.91 Yield stress MPA DIN EN ISO 527 32 ELONGATION AT BREAK % DIN EN ISO 527 70 ELONGATION AT YIELD % DIN EN ISO 527 32 MODULUS OF ELASTICITY MPA DIN EN ISO 527 1400 SHORE D HARDNESS - ISO 868 70 SHOCK RESISTANCE KJ/m 2 DIN EN ISO 179 NR RESILIENCE KJ/m 2 DIN EN ISO 179 7 DYNAMIC FRICTION COEFFICIENT - ISO/DTR7147 - THERMAL MELTING POINT °C - 164 OPERATING TEMPERATURE °C - 0/+100 COEFFICIENT OF LINEAR EXPANSION K
- the assembly by spray thermal fusion of the spunbond on the meltblown improves the properties of filtration of the materials for half masks evaluated according to the standard EN149: the PP material produced by the combining of the two fabrics has the features indicated in the Table 2 below, which correspond to the specifications of the FFP2 class.
- Table 2 Pressure drop or breathability ( ⁇ P) 2 Penetration ⁇ P after P.O Sat Penetration after P.O. Sat ⁇ P after storage Penetration after storage (mm) Pa/cm 2 % Pa/cm 2 % Pa/cm 2 % Pa/cm 2 % 50+/-10 >95 55+/-10 >94 50+/-10 >94
- the material with two layers has a thickness of approximately 0.5 mm and is therefore thinner and therefore lighter than those conventionally used for FFP2 masks.
- the two-layer material is cut into the shapes and into the sizes required to form the final product.
- Elastics or ties are applied to the mask, connected using glues already tested and approved for food or biomedical use.
Landscapes
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Business, Economics & Management (AREA)
- Emergency Management (AREA)
- Physical Education & Sports Medicine (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Respiratory Apparatuses And Protective Means (AREA)
- Filtering Materials (AREA)
Abstract
The object of the present invention is the preparation of an FFP2NR-type mask made up solely of two layers of meltblown nonwoven fabric with high filtering power bonded through thermal fusion with a layer of spunbond fabric.
Description
- The subject of the present invention is the preparation of an FFP2NR-type mask made up solely of two layers of meltblown nonwoven fabric with high filtering power bonded through thermal fusion to a layer of spunbond fabric.
- FFP2-type face masks are able to filter up to 94% of particles suspended in the air equal to 0.6 µm in size. They provide effective protection against smoke, dust, aerosols, bacteria and viruses. Face masks with filtering capacity are obtained by using generally two different types of nonwoven fabric superimposed according to combinations that vary according to the type of mask. Spunbond nonwoven fabric has the main function of mechanical support and of comfort in contact with the skin of those who wear them, while meltblown nonwoven fabric, with a denser weave, guarantees filtering capacity and breathability. The main function, that is the filtering capacity, is therefore guaranteed above all by the meltblown layer.
- Meltblown nonwoven fabric is prepared through extrusion of the melted polymer, typically polypropylene, by means of a particular "blown spinning" technology. In this way long and very thin fibres are produced which are stretched and cooled by blowing warm air while the fibres are projected onto a collection support (a cylinder or another appropriate surface). In this way a strip of finely entangled microfibres is created which is collected into rolls and subsequently converted into finished products. The fibres produced in this way are extremely fine.
- According to the spunbond technique, the fibres of polypropylene (PP) are spun and then dispersed directly onto a baffle net by means of air jets. The spunbond technology allows high speeds and economical production costs. The PP microfibres are bonded by resins or thermally. There are different variants of the spunbond spinning technology. Polypropylene (PP) spunbonds are produced with even higher speed and at decidedly lower temperatures with respect to nonwoven fabrics of different composition, exploiting the lower melting point.
- The spunbond technology allows nonwoven fabrics to be obtained that are characterised by microfibres of larger size with respect to the meltblown technology. On the other hand the spunbond nonwoven fabrics are decidedly more robust. The larger microfibres of spunbond spinning do not confer high filtering capacity which is instead guaranteed by the meltdown nonwoven fabric.
- For this reason, the meltblown (M) is already bonded in production (or subsequently) with yarn generated with the spunbond technology (S). Thus so-called "SM" or "SMS" (spun-melt-spun) tapes are obtained. These "composite" nonwoven fabrics combine the properties of the two spinning technologies. They are in fact adequately robust and have the microfiltering advantages of very fine fibres. The masks are typically constituted by the superimposing of at least three layers of nonwoven fabric with different functions and features: normally an external layer of hydrophobic spunbond (S) nonwoven fabric, with good mechanical strength, a filtering layer of meltblown (M) nonwoven fabric, made up of smaller microfibres (1-3 m), and an internal layer again of hydrophobic and biocompatible spunbond (S) nonwoven fabric intended to come into contact with the skin.
- Only nonwoven fabric with at least three layers (S-M-S) is able to date to meet the requirements of efficacy of the filtration capacity (PFE) and of breathability of the mask. The devices currently available are mostly made up of a minimum of 4 to a maximum of 6 layers of nonwoven fabric.
- The object of the present invention is the manufacture of an ergonomic, lightweight and breathable face mask able to ensure the filtering performances provided by the EN149 standard in force.
- It has now surprisingly been found that this object can be achieved using only two layers, one of meltblown polypropylene and one of spunbond polypropylene appropriately bonded.
- The solution proposed by the invention is advantageous and overcomes the disadvantages of the prior art connected to multilayer configurations rather than simply with two layers, not only maintaining the filtration efficacy of traditional masks but also improving it.
- FFP2-type face masks, the object of the invention, are made up of a material with two layers obtained by thermal fusion of a layer of meltblown polypropylene with grammage of 30-50g/m2 on a layer of spunbond polypropylene nonwoven fabric with grammage of 30-50g/m2.
- The density of the material with two layers which makes up the mask of the invention is typically comprised between 0.90 and 0.96 kg/dm3.
- The thermal fusion of the layer of meltblown polypropylene on the layer of spunbond polypropylene nonwoven fabric takes place at a temperature of 150-200°C, preferably 160°C approximately.
- The spunbond polypropylene is a nonwoven fabric made up of continuous filaments in 100% polypropylene arranged randomly and welded thermally via a calendering process.
- The meltblown is made up of polypropylene microfibres with diameter 2 nm.
- The meltblown is characterised by the extrusion of the melted polymer by means of a particular technology of blown spinning. By means of the stretching action of a flow of compressed and overheated air, the mass of melted polymer is transformed into long and very thin fibres which are projected onto a collection support traversed by a cooling air flow. In this way a veil of finely entangled microfibres is created which is collected in reels and subsequently converted into finished products.
- Table 1 here below are the technical features - mechanical-dielectric-thermal - of the polypropylene used for the production of the masks.
Table 1 PROPERTIES UNIT OF MEASUREMENT METHOD PP MECHANICAL SPECIFIC WEIGHT g/cm3 ISO 1183 0.91 Yield stress MPA DIN EN ISO 527 32 ELONGATION AT BREAK % DIN EN ISO 527 70 ELONGATION AT YIELD % DIN EN ISO 527 32 MODULUS OF ELASTICITY MPA DIN EN ISO 527 1400 SHORE D HARDNESS - ISO 868 70 SHOCK RESISTANCE KJ/m2 DIN EN ISO 179 NR RESILIENCE KJ/m2 DIN EN ISO 179 7 DYNAMIC FRICTION COEFFICIENT - ISO/DTR7147 - THERMAL MELTING POINT °C - 164 OPERATING TEMPERATURE °C - 0/+100 COEFFICIENT OF LINEAR EXPANSION K-1 DIN 53752 1.64X10-4 THERMAL CONDUCTIVITY W/m•K DIN 52612 0.22 COMBUSTION BEHAVIOUR - UL94 HB DIELECTRIC DIELECTRIC RIGIDITY KV/mm IEC243-1 52 SURFACE RESISTANCE OHM DINIEC167 1014 - The assembly by spray thermal fusion of the spunbond on the meltblown improves the properties of filtration of the materials for half masks evaluated according to the standard EN149: the PP material produced by the combining of the two fabrics has the features indicated in the Table 2 below, which correspond to the specifications of the FFP2 class.
Table 2 Pressure drop or breathability (ΔP)2 Penetration ΔP after P.O Sat Penetration after P.O. Sat ΔP after storage Penetration after storage (mm) Pa/cm2 % Pa/cm2 % Pa/cm2 % 50+/-10 >95 55+/-10 >94 50+/-10 >94 - The data given show that the material with two layers of the invention improves the performances both of breathability and of filtration. The tests which the face masks of the invention underwent indicated improved respiratory performances, bringing the values from 2.9/2.8 to 2.4/2.3.
- The material with two layers has a thickness of approximately 0.5 mm and is therefore thinner and therefore lighter than those conventionally used for FFP2 masks. The two-layer material is cut into the shapes and into the sizes required to form the final product.
- Elastics or ties are applied to the mask, connected using glues already tested and approved for food or biomedical use.
- Thanks to the use of a lightweight and thin material it is possible to make masks that also meet in full criteria of aesthetics (applying for example designs with continuous elements imprinted at the sides which highlight the simplicity of the design thereof) and ergonomics (adaptability to the anatomy of the face, lack of friction, easy and intuitive use).
Claims (3)
- FFP2-type face masks consisting of a two-layer material obtained by thermally fusing a layer of meltblown polypropylene with grammage of 30-50g/m2 onto a layer of spunbond nonwoven polypropylene fabric with grammage of 30-50g/m2.
- Masks according to claim 1 wherein the density of the two-layer material is 0.90-0.96 kg/dm3.
- Masks according to claim 1 or 2 wherein thermal fusion is carried out by spraying the meltblown polypropylene layer onto the spunbond nonwoven polypropylene layer at a temperature of 150-200°C, preferably 160°C.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IT202200012464 | 2022-06-13 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP4292670A1 true EP4292670A1 (en) | 2023-12-20 |
Family
ID=83081171
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP23178511.4A Pending EP4292670A1 (en) | 2022-06-13 | 2023-06-09 | Ffp2-type filter face masks with two layers |
Country Status (1)
Country | Link |
---|---|
EP (1) | EP4292670A1 (en) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005124777A (en) * | 2003-10-23 | 2005-05-19 | Kurashiki Seni Kako Kk | Infection prevention mask |
CH717300A2 (en) * | 2020-04-07 | 2021-10-15 | Flawa Consumer Gmbh | Protective mask. |
-
2023
- 2023-06-09 EP EP23178511.4A patent/EP4292670A1/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005124777A (en) * | 2003-10-23 | 2005-05-19 | Kurashiki Seni Kako Kk | Infection prevention mask |
CH717300A2 (en) * | 2020-04-07 | 2021-10-15 | Flawa Consumer Gmbh | Protective mask. |
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