WO2002041717A2 - Media de filtration pour masque facial a meilleure respirabilite - Google Patents
Media de filtration pour masque facial a meilleure respirabilite Download PDFInfo
- Publication number
- WO2002041717A2 WO2002041717A2 PCT/US2001/044371 US0144371W WO0241717A2 WO 2002041717 A2 WO2002041717 A2 WO 2002041717A2 US 0144371 W US0144371 W US 0144371W WO 0241717 A2 WO0241717 A2 WO 0241717A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- polymer
- fibers
- face mask
- weight
- pulp
- Prior art date
Links
Classifications
-
- 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 present invention relates to faces masks in general, and more particularly to an improved filtration media for faces masks.
- a face mask is important to protect both the patient and the health care practitioner.
- many industrial applications also require wearing protective face masks to reduce dust particles and other contaminants in the air as well as to protect workers from possibly hazardous chemicals and/or bacteria.
- a important concern with any of the various face masks is to provide comfortable, low cost, and effective filtering and protection. Materials are known and available to allow the free passage of air through the body of the face mask for breathing and to prevent the passage of bacteria, aerosols, and other liquid or particulate contaminants.
- Conventional face masks are typically formed of multiple layers, including an inner layer and a generally coextensive outer layer. One or more filtration layers are typically disposed between the inner and outer layers.
- meltblown nonwoven webs are known to provide excellent liquid and particulate filtration properties.
- the meltblown web can be formed using any of various polymer fiber forming materials know to those in the art, including polypropylene, polyester, and the like.
- breathability of a face mask is a factor of the pressure drop across the mask and is dictated primarily by the permeability of the filtration media. Industry standards typically require a pressure drop of
- U.S. patent No. 5,780,153 describes an electret-like filtration web made of ionomer copolymer fibers possessing electret-like surface characteristics without deliberate post-charge treatment of the fibers or web.
- the '153 patent also describes an improved filtration web formed of blends of either polypropylene or polyethylene and 20% to 50% of the ionomer resin.
- the art is continuously seeking to improve filtration media used particularly in face masks without adversely affecting the breathability or comfort of the masks.
- the present invention provides such an improvement.
- the invention provides an improved face mask filtration media, and an improved face mask incorporating the filtration media.
- the style or configuration of the face mask is not particularly important.
- the filtration media according to the present invention can be utilized in any face mask configuration requiring a filtration layer or media.
- Such masks generally include a body configured to fit over the nose and mouth of the wearer, and at least one layer of filtration media disposed between an inner layer and an outer layer.
- the filtration media is a meltblown polymer/pulp coform web formed of a matrix of meltblown polymer fibers with individual pulp fibers disposed throughout. It should be understood that the invention is not limited to any particular polymer.
- a polypropylene based polymer is particularly well suited for face mask applications.
- the coform web may contain about 2% to about 50% by weight of the pulp fibers. The pulp fibers engage and hold the polymer fibers apart and thus add significantly to an increase in permeability of the web without affecting filtration characteristics of the web.
- the coform web may also possess filtration characteristics enhanced by an electret additive blended with the polymer.
- the electret additive may be barium titanate and malic anhydride, for example about 1% by weight of barium titanate and about 5% by weight of malic anhydride.
- the electret additive is an ionomer polymer and may also include barium titanate.
- the ionomer polymer may be about 20% to about 50% by weight of the polymer blend and the barium titanate about 1% by weight of the polymer blend.
- a face mask filtration media in accordance with the present invention has shown to possess a significantly reduced pressure drop (translating to a face mask having greatly improved breathability) while having an equal filtration efficiency as compared to a conventional meltblown polypropylene web typically utilized in face mask applications.
- FIG. 1 is a perspective view of one style of conventional face mask applicable to the present invention.
- Fig. 2 is a front and partial cut-away view of the conventional mask of Fig. 1 illustrating various structural components of such face masks.
- any given range is intended to include any and all lesser included ranges.
- a range of from 45-90 would also include 50-90; 45-80; 46-89; and the like.
- the present invention relates generally to a face mask incorporating an improved filtration media.
- An exemplary face mask structure is illustrated in Figs. 1 and 2.
- the mask 10 includes a pleated body 12 defined between an upper edge 36, a lower edge 34, and sides 32. Tie straps 16 and 18, or any other suitable means or devices are provided for securing the mask 10 over the nose and mouth of the wearer 14.
- the body 12 is formed by a plurality of layers.
- face masks include an inner layer 30 and an outer layer 22.
- the inner and outer layers can be formed of various materials known to those skilled in the art. Any number of additional layers, for example a barrier layer 26, may also be included.
- At least one intermediate layer is typically provided in the form of a filtration media layer 28. The focus of this invention is on the filtration media layer.
- the present invention is not limited to any particular type or style of face mask, and that the pleated style mask of Fig. 1 is shown for illustrative purposes only.
- the filtration media according to this invention may be incorporated into any face mask style or configuration.
- Exemplary faces masks are described and shown, for example, in the following U.S. patents: 4,802,473; 4,969,457; 5,322,061; 5,383,450; 5,553,608; 5,020,533; and 5,813,398. These patents are incorporated herein in their entirety for all purposes.
- the filtration media according to the invention is comprised of a nonwoven web (for example a meltblown web) of polymer fibers having a multiplicity of individual pulp fibers disposed throughout the matrix of polymer fibers.
- the pulp fibers engage at least some of the polymer fibers and hold the polymer fibers apart thereby increasing the permeability of the filtration web.
- the polymer may also include an electret additive to increase the filtration efficiency of the overall web.
- nonwoven web refers to a structure of individual fibers or filaments which are interlaid, but not in an identifiable repeating manner as in a knitted fabric.
- Nonwoven webs can be formed by a variety of processes known to those skilled in the art, such as meltblowing, spunbonding, and bonded carded web processes.
- the term "polymer” generally includes, but is not limited to, homopolymers, copolymers, such as block, graft, random, and alternating copolymers, terpolymers, etc. and blends and modifications thereof.
- the term "polymer” shall include all possible geometric configurations of the material.
- meltblown fibers refers to fibers formed by extruding a molten polymer material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into a high velocity gas (e.g. air) stream which attenuates the filaments of molten polymer material to reduce their diameters, which may be to microfiber (not greater than 100 microns) diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers.
- the meltblown process is well-known and is described in various publications, including NRL Report 4364, "Manufacture of Super-Fine Organic Fibers" by V. A. Wendt, E. L. Boone, and C. D. Fluharty; NRL Report 5265, "An Improved Device for the Formation of Super-Fine Thermoplastic Fibers" by K.D. Lawrence,
- pulp refers to pulp containing fibers from natural sources such as woody and non-woody plants.
- Woody plants include, for example, deciduous and coniferous trees.
- Non- woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute hemp, and bagasse.
- Frazier Porosity is a standard measure in the non-woven web art of the permeability of the material (units in cubic feet per square foot per minute). The procedure used to determine Frazier air permeability is in accordance with the specifications of method 5450, Federal Test Methods Standard No. 191.
- Filtration efficiencies of nonwoven webs may be evaluated using a TSI Inc. (St. Paul, Minn.) Model 8110 Automated Filter Tester (AFT).
- the Model 8110 AFT measures pressure drop (in mm. of water) and particle filtration characteristics for air filtration media.
- the AFT utilizes a compressed air nebulizer to generate a filter "challenge" aerosol of sodium chloride particles. Typical air flow rates are between 31 liters per minute and 33 liters per minute through a sample area of the filter medium.
- the filtration efficiency is expressed as the percentage of sodium chloride particles which penetrate the filter.
- Penetration is defined as transmission of a particle through the filter medium which are detected downstream of the medium.
- the percent penetration (%P) reflects the ratio of the downstream particle count to the upstream particle count.
- the pulp/polymer fiber web may be formed in a continuous online "coforming" process.
- the resulting webs are often referred to as "coform" webs.
- U.S. Pat. No. 4,100,324 describes a process and apparatus for making such webs, which are described as having a unique combination of strength, absorbency, and hand.
- the '324 patent is incorporated herein in its entirety for all purposes.
- U.S. Pat. No. 5,350,624 likewise describes a coforming process that is particularly suited for manufacturing the filtration web according to the present invention.
- the '624 patent is also incorporated herein in its entirety for all purposes.
- the pulp/polymer coform web exhibits and increased porosity (reduced pressure drop) due primarily to the entanglement of the pulp and polymer fibers.
- the material is formed by initially forming a primary airstream containing the meltblown fibers and forming a secondary airstream containing the pulp fibers.
- the two airstreams are merged under turbulent conditions to form an integrated airstream containing a homogenous mixture of the pulp and meltblown fibers.
- the integrated airstream is directed onto a forming surface to form the coform web. Because the polymer fibers are longer, thinner, and more flexible than the pulp fibers, they twist around and entangle the relatively short, thick, and stiffer pulp fibers as soon as the two fiber streams merge in the forming process.
- the entanglement interconnects the two different types of fibers with strong, persistent inter-fiber attachments without any significant molecular, adhesive, or hydrogen bonds.
- the polymer fibers are spaced apart by engagement with the relatively stiff pulp fibers and, thus, the resulting coform web retains a high degree of porosity.
- the invention is not limited to a particular polymeric material.
- Polymers suitable for this invention can be selected from any fiber- forming polymer.
- Representative polymers include polyolefin, e.g. polypropylene, polyethylene, polymethylpentente, polyester, and polyurethane.
- Meltblown polyolefin fibers have proven well suited for face mask filter media applications, particularly polypropylene based fibers.
- the invention is described herein as a meltblown polypropylene fiber web, it should be appreciated, however, that a number of suitable polymers or polymer blends are known in the art and can be used to form the polymer fiber component of the present coform web.
- the pulp content of the filtration web according to the invention ranges from about 2% to about 50% by weight of the web, and particularly between about 15% to about 35%. As described in the illustrative Example herein, an optimum amount of about 25% pulp content has demonstrated significantly improved breathability (pressure drop) with equivalent filtration properties as compared to a meltblown web without a pulp fiber component.
- the filtration coform media according to the invention may also preferably include an electret additive package added to the molten polymer to increase the filtration characteristics of the resulting meltblown web.
- the electret additive package may be in accordance with U.S. Pat. No. 5,780,153 (incorporated herein).
- the additive package is an ionomer resin blended with the polyolefin (e.g.
- the ionomer additive package may be added in a range of from about 20% to about 59% by weight of the polymer blend.
- barium titanate is also added to the blend in an amount of about 1 % by weight.
- An alternative electret additive that has proven useful is a package of 1% barium titanate and 5% malic anhydride olefin copolymer.
- the present filtration coform media is not limited in its basis weight.
- Various basis weight coforms may be utilized depending on the particular desired face mask configuration. Generally the basis weight ranges from about 5 gsm (grams per square meter) to about 50 gsm.
- a particularly well suited coform may have a basis weight of about 25 gsm.
- EXAMPLE A polymer/pulp coform was made in accordance with the present invention.
- the coform had a total basis weight of 25 gsm ( 20 gsm meltblown polypropylene (PF-015) and 5 gsm of softwood pulp).
- the coform was made substantially in accordance with U.S. Pat. No. 5,350,624.
- a comparative example was also made consisting of a 20 gsm meltblown polypropylene web.
- the coform was tested against the comparative example for filtration efficiency and pressure drop using the Automated Filter Tester (AFT) described above.
- AFT Automated Filter Tester
- the coform had a 31% lower pressure drop and essentially equal filtration efficiency as compared to the meltblown comparative example.
Landscapes
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Physical Education & Sports Medicine (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Respiratory Apparatuses And Protective Means (AREA)
- Filtering Materials (AREA)
Abstract
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA03004429A MXPA03004429A (es) | 2000-11-27 | 2001-11-27 | Medios de filtracion de mascara para la cara con capacidad para respirar mejorada. |
AU2002233940A AU2002233940A1 (en) | 2000-11-27 | 2001-11-27 | Face mask filtration media with improved breathability |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US72284100A | 2000-11-27 | 2000-11-27 | |
US09/722,841 | 2000-11-27 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2002041717A2 true WO2002041717A2 (fr) | 2002-05-30 |
WO2002041717A3 WO2002041717A3 (fr) | 2003-01-16 |
Family
ID=24903619
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/044371 WO2002041717A2 (fr) | 2000-11-27 | 2001-11-27 | Media de filtration pour masque facial a meilleure respirabilite |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU2002233940A1 (fr) |
MX (1) | MXPA03004429A (fr) |
WO (1) | WO2002041717A2 (fr) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6644314B1 (en) * | 2000-11-17 | 2003-11-11 | Kimberly-Clark Worldwide, Inc. | Extensible and retractable face mask |
WO2004002251A1 (fr) * | 2002-06-28 | 2004-01-08 | Kimberly-Clark Worldwide, Inc. | Masque facial en stratifie encolle au tissage/souffle en fusion/encolle au tissage |
FR2854808A1 (fr) | 2003-05-16 | 2004-11-19 | Robert Schegerin | Filtre interne amovible de masque a mise en place rapide pour pilotes d'avions |
US20120060258A1 (en) * | 2009-05-29 | 2012-03-15 | Stewart Neal G | Composition for use in decreasing the transmission of human pathogens |
CN112111993A (zh) * | 2020-08-05 | 2020-12-22 | 辽宁森林木纸业有限公司 | 一种高效热熔布 |
TWI729229B (zh) | 2016-10-17 | 2021-06-01 | 日商Nbc紗網技術股份有限公司 | 口罩 |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4802473A (en) | 1983-11-07 | 1989-02-07 | Tecnol, Inc. | Face mask with ear loops |
US4969457A (en) | 1987-10-02 | 1990-11-13 | Tecnol, Inc. | Body fluids barrier mask |
US5020533A (en) | 1987-10-02 | 1991-06-04 | Tecnol, Inc. | Face mask with liquid and glare resistant visor |
US5322061A (en) | 1992-12-16 | 1994-06-21 | Tecnol Medical Products, Inc. | Disposable aerosol mask |
US5350620A (en) | 1989-11-14 | 1994-09-27 | Minnesota Mining And Manufacturing | Filtration media comprising non-charged meltblown fibers and electrically charged staple fibers |
US5383450A (en) | 1987-10-02 | 1995-01-24 | Tcnl Technologies, Inc. | Liquid shield visor for a surgical mask |
US5553608A (en) | 1994-07-20 | 1996-09-10 | Tecnol Medical Products, Inc. | Face mask with enhanced seal and method |
US5813398A (en) | 1996-03-29 | 1998-09-29 | Tecnol Medical Products, Inc. | Combined anti fog and anti glare features for face masks |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4100324A (en) * | 1974-03-26 | 1978-07-11 | Kimberly-Clark Corporation | Nonwoven fabric and method of producing same |
US4215682A (en) * | 1978-02-06 | 1980-08-05 | Minnesota Mining And Manufacturing Company | Melt-blown fibrous electrets |
GB8512206D0 (en) * | 1985-05-14 | 1985-06-19 | Kimberly Clark Ltd | Non-woven material |
GR900100242A (el) * | 1989-04-07 | 1991-09-27 | Johnson & Johnson Medical | Ηλεκτροστατικώς φορτιζόμενη μάσκα καλύψεως προσώπου και μέ?οδος κατασκευής της. |
US5350624A (en) * | 1992-10-05 | 1994-09-27 | Kimberly-Clark Corporation | Abrasion resistant fibrous nonwoven composite structure |
US5658640A (en) * | 1993-08-17 | 1997-08-19 | Minnesota Mining And Manufacturing Company | Electret filter media having an undulated surface |
US5817584A (en) * | 1995-12-22 | 1998-10-06 | Kimberly-Clark Worldwide, Inc. | High efficiency breathing mask fabrics |
US5817415A (en) * | 1996-09-12 | 1998-10-06 | E. I. Du Pont De Nemours And Company | Meltblown ionomer microfibers and non-woven webs made therefrom for gas filters |
ZA984078B (en) * | 1997-05-30 | 1998-11-25 | Kimberly Clark Wordlwide Inc | Face mask |
US6102039A (en) * | 1997-12-01 | 2000-08-15 | 3M Innovative Properties Company | Molded respirator containing sorbent particles |
-
2001
- 2001-11-27 AU AU2002233940A patent/AU2002233940A1/en not_active Abandoned
- 2001-11-27 WO PCT/US2001/044371 patent/WO2002041717A2/fr not_active Application Discontinuation
- 2001-11-27 MX MXPA03004429A patent/MXPA03004429A/es unknown
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4802473A (en) | 1983-11-07 | 1989-02-07 | Tecnol, Inc. | Face mask with ear loops |
US4969457A (en) | 1987-10-02 | 1990-11-13 | Tecnol, Inc. | Body fluids barrier mask |
US5020533A (en) | 1987-10-02 | 1991-06-04 | Tecnol, Inc. | Face mask with liquid and glare resistant visor |
US5383450A (en) | 1987-10-02 | 1995-01-24 | Tcnl Technologies, Inc. | Liquid shield visor for a surgical mask |
US5350620A (en) | 1989-11-14 | 1994-09-27 | Minnesota Mining And Manufacturing | Filtration media comprising non-charged meltblown fibers and electrically charged staple fibers |
US5322061A (en) | 1992-12-16 | 1994-06-21 | Tecnol Medical Products, Inc. | Disposable aerosol mask |
US5322061B1 (en) | 1992-12-16 | 1998-06-02 | Tecnol Med Prod Inc | Disposable aerosol mask |
US5553608A (en) | 1994-07-20 | 1996-09-10 | Tecnol Medical Products, Inc. | Face mask with enhanced seal and method |
US5813398A (en) | 1996-03-29 | 1998-09-29 | Tecnol Medical Products, Inc. | Combined anti fog and anti glare features for face masks |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6644314B1 (en) * | 2000-11-17 | 2003-11-11 | Kimberly-Clark Worldwide, Inc. | Extensible and retractable face mask |
WO2004002251A1 (fr) * | 2002-06-28 | 2004-01-08 | Kimberly-Clark Worldwide, Inc. | Masque facial en stratifie encolle au tissage/souffle en fusion/encolle au tissage |
FR2854808A1 (fr) | 2003-05-16 | 2004-11-19 | Robert Schegerin | Filtre interne amovible de masque a mise en place rapide pour pilotes d'avions |
US7575006B2 (en) | 2003-05-16 | 2009-08-18 | Intertechnique | Respirator mask with hygienic protection |
USRE44545E1 (en) | 2003-05-16 | 2013-10-22 | Intertechnique | Respirator mask with hygienic protection |
US20120060258A1 (en) * | 2009-05-29 | 2012-03-15 | Stewart Neal G | Composition for use in decreasing the transmission of human pathogens |
US9963611B2 (en) * | 2009-05-29 | 2018-05-08 | Innonix Technologies, Incorporated | Composition for use in decreasing the transmission of human pathogens |
TWI729229B (zh) | 2016-10-17 | 2021-06-01 | 日商Nbc紗網技術股份有限公司 | 口罩 |
US11363844B2 (en) | 2016-10-17 | 2022-06-21 | Nbc Meshtec Inc. | Mask |
CN112111993A (zh) * | 2020-08-05 | 2020-12-22 | 辽宁森林木纸业有限公司 | 一种高效热熔布 |
Also Published As
Publication number | Publication date |
---|---|
MXPA03004429A (es) | 2003-08-19 |
WO2002041717A3 (fr) | 2003-01-16 |
AU2002233940A1 (en) | 2002-06-03 |
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