WO2022054108A1

WO2022054108A1 - Respiratory moisture-regulating face four-layer mask with full attachment on the face

Info

Publication number: WO2022054108A1
Application number: PCT/IR2021/050019
Authority: WO
Inventors: Amir Sajad SAEIDI
Original assignee: Saeidi Amir Sajad
Priority date: 2020-09-08
Filing date: 2021-08-26
Publication date: 2022-03-17

Abstract

Feeling of suffocation and heaviness of breath, irritation, inflammation of the face skin, pain behind the ear due to the mask strap, escape of unfiltered air around the mask, slipping the mask over the nose while talking, etc. are problems that a person suffers from using ordinary masks. This invention is a four-layer antibacterial mask that controls respiratory moisture by strong triple absorbents (Alg, PAN, KGOK), high resistance to physical damage, and complete attachment with medical-grade acrylic adhesive. It absorbs the exhalation moisture up to 30-60% with the help of its triple polymers and provides completely regulated breathing air with a moisture content of 40-70%. Also, the complete attachment of the mask on the face without a strap using medical-grade acrylic adhesive prevents skin inflammation, pain behind the ears and nose, penetration of air and contaminants, or slipping the mask over the face perfectly preserves the person's health.

Description

Respiratory moisture-regulating face four-layer mask with full attachment on the face

This invention relates to multilayer breathing masks, which can be considered as a subset of health, treatment, and safety devices in various industries.

A description of the state of prior knowledge and a history of advances related to the claimed invention:

Based on reviewing the Patentscope website and analyzing similar inventions, so far six inventions with the keywords "Mask, Moisture, Absorb" have been registered as inventions in the field of health. Below is information on all of them obtained from the Patentscope website and only three of these six inventions have been registered with the PCT International Convention.

1. Invention entitled "ANNULAR UNIT FOR MOISTURE MANAGEMENT IN RESPIRATORY MASK" with International Application No. PCT/CN2015/000845 and Publication Number WO/2017/091920

2. The invention entitled "REUSABLE SILICA-GEL MOISTURE ABSORPTION DEVICE DESIGNED TO REDUCE MOISTURE INSIDE A MASK" with International Application No. PCT/CN2015/091829 and Publication Number WO/2017/063137

3. Invention entitled "SYSTEM AND METHOD FOR ABSORBING MOISTURE WITHIN A FACE MASK" with International Application No. PCT/CN2017/112579 and Publication Number WO/2019/100285

4. Invention entitled "ANNULAR UNIT FOR MOISTURE MANAGEMENT IN RESPIRATORY MASK" with Application Number 17095576 and Publication Number 20210060364

5. Invention entitled "Moisture-proof mask" with Application Number 202020609355.1 and Publication Number 212545675

6. The invention entitled "One-way moisture-conducting antibacterial mask" with Application Number 202010951753.6 and Publication Number 112043024

The main differences and new aspects of our invention, which completely distinguish this one from above inventions, are:

Our mask consists of four layers, while none of the previous inventions are four-layer, and the main material of our mask is 3 types of strong moisture-absorbing polymers "Alg, PAN, KGOK" which has not been used in any of the previous inventions.

In this mask unlike the others, "KGOK" material with antibacterial properties has been used to improve disinfection of the mask.

None of the previous inventions can regulate the optimal respiratory humidity in the range of 40% -70% humidity.

Our mask has a high physical resistance to damage and tearing, which has a definite advantage over the old vulnerable masks.

In our invention, the strap is generally removed from the mask, and it is completely attached to the face because of using medical grade adhesive, so the problems of previous inventions that use the strap have been solved.

In all previous inventions, due to the use of the strap, it is possible for polluted air to penetrate from around, while in this invention, after attaching the mask to the face with medical grade adhesive, the respiratory space is completely isolated from the surroundings.

In this invention, a suitable medical grade adhesive without any skin allergies has been used, which has not been used in any of the previous inventions.

This invention has two air filter layers while previous inventions don't have this advantage. ( - Layer 2 and Layer 3)

One of the factors that should be considered for accurate measurement of lung function is air humidity. Today, the use of masks by medical staff and people in the face of respiratory pathogens (e.g. viruses and bacteria) and by industrial workers who work in the air contaminated with harmful particles, has become a necessity. Due to the problems and inconveniences caused by using masks for people, this invention aimed to facilitate the use of masks, comfort while using, increase the mask durability, and encourage the public to use it. Due to the fact that a very small amount of moisture passes through the mask and the inner layer has very little ability to absorb it, the heat and moisture caused by the exhalation inside the mask increase unbearably, and on the other hand, with the penetration of this moisture in the fibers of the filters, the resistance of the mask against the passage of air increases, which gives the person a feeling of suffocation and heavy breathing. Moreover, if the breathing air is completely dry and free of moisture without the measurements and only with the use of absorbent, the dried air causes problems for the person, such as a feeling of pain, irritation, or dissatisfaction in the nasal mucosa. Also, the straps and clips of these masks cause many problems while using, such as the irritation of the ears due to the straps, the inflamed line on the face and nose due to the long-term use of mask, the escape of unfiltered air from the edges of the mask, and slipping the mask over the nose while talking. Furthermore, the metal clip on the nose not only does not prevent air escape from the top of the mask but also causes fogging of the glasses, decreasing the vision, and can be annoying for the person. Current masks have little resistance to physical damage, and if not used properly during use or wearing, they may tear or pores may form, endangering the person's health. Some masks that have two pieces of adhesive on both sides instead of straps have many problems, including the escape of air around the mask, and reduction of the desired amount of adhesion when the skin is wet.

As a result, to eliminate such problems, this invention has been designed and made with effective and proportionate absorption of respiratory moisture by using several types of moisture-absorbers, and adjusting the amount of moisture inside the mask, for easy breathing. On the other hand, viruses and bacteria that cause diseases such as COVID-19, influenza, colds, etc., and are often present in saliva released when the patient sneezes, breathes, or coughs, by contact, are trapped in contact with absorbent fibers; so using this invention can be an effective way to prevent or reduce the transmission of these infectious diseases. Also, by using the appropriate adhesive and completely covering the area around the mask, it eliminates physical problems and air escape and leads to the complete elimination of the mask's defects.

The main novelty in this invention is the three moisture-absorbing materials, which in addition to moisture absorption, have different properties such as strength, antibacterial effect, absorption of suspended particles, and double filtration, making an ideal mask. Moreover, the full attachment of the mask on the face by medical-grade adhesive prevents the penetration of any contamination and polluted air. Production of this mask provides comfort for the person and improving the structure and replacing some components of ordinary masks, in addition to being easier for people to use, has also increased the durability of the mask.

Using suitable and strong moisture-absorbers, the amount of moisture inside the mask is kept at a desirable and acceptable level, to reduce the difficulty of breathing and increase the uncomfortable temperature inside the mask so that the person does not feel suffocated during long-term use. Also, using complete adhesive instead of sectional adhesive or straps, as well as antibacterial materials in the design of this mask causes complete protection of the mask, and penetration of suspended particles, polluted air, viruses, and bacteria has become almost impossible. Therefore it is much easier and safer to use. Problems such as pain in the back of the ear, inflamed lines on the face due to long-term use of the mask, especially in the treatment staff and those who frequently use mask, pain on the nose caused by the metal clip, and possible physical damage to the mask such as rupture and holes have been resolved in this invention.

Due to the use of straps or sectional adhesive in their design, previous inventions were problematic for the person when speaking and caused the mask to slip from the nose. This problem has been eliminated in this invention. Ultimately, being disposable and having adhesive prevent the repeated use and frequent removal of the mask from the face, and consequently, prevents the penetration of contamination. In summary, the advantages of this mask are as follows:

1- Adjustment of respiration moisture between 40-70% for ideal respiration using strong absorbers

2- Air quality control to prevent suffocation and respiratory depression throughout the use

3- High strength and resistance to tearing and holes and providing an isolated breathing environment

4- Ability to fully connect on the face without leaving any way for polluted air to penetrate

5- Complete filtration of polluted air and its removal from viruses, bacteria, microbes, suspended particles, etc.

6- Antibacterial-Antimicrobial properties with a high ability to eliminate pathogens

7- Suitable medical-grade adhesive without causing any skin allergies while using

8- Prevent air escape and create a completely isolated space to prevent the penetration of any contamination

9- Prevent slipping the mask on the face during talking or daily activities

10- Complete elimination of pain behind the ears, metal clip on the nose, and inflamed lines on the face due to long0-term use

11- Prevent the use of a mask several times beyond its durability and safety

12- Prevent the face from getting wet or sweating, ease of use, and complete comfort of the person

Chemical formula (Alg) - Chemical synthesis of sodium alginate copolymer (linear polysaccharide)

Chemical formula (KGOK) - Synthesis of KGOK from Konjac Glucomannan Oligosaccharide using kojic acid

Chemical formula (PAN) - Synthesis of polyacrylonitrile (PAN) from semi-crystalline synthetic polymers with linear formula (C3H3N)n

Chemical formula (medical-grade acrylic adhesive) - Copolymeric synthesis of pressure-sensitive acrylic adhesive from three acrylate monomers

Diagram - Alg dehumidifier performance vs time (absorption continues until sodium alginate is saturated).

Diagram - PAN dehumidifier performance vs the humidity level and different temperatures

Diagram - KGOK dehumidifier performance vs time and in two different humidity levels

Mask from the side view

Mask from the front view

Different layers of the mask and the structure of their components:

( - Layer 1 - Section A: Spunbond)

( - Layer 1 - Section B: Medical-grade acrylic adhesive)

( - Layer 2 - Section C: Tube of Alg gel)

( - Layer 2 - Section D: PAN fibers)

( - Layer 3 - Section E: KGOK crystalline particles)

( - Layer 3 - Section F: Melt blown)

( - Layer 4 - Section G: Spunbond)

( - Layer 4 - Section H: several folds)

How to attach the mask to the face

Since a very small amount of moisture passes through the mask and the inner layer has very little ability to absorb it, the heat and moisture caused by the exhalation inside the mask increase unbearably, and on the other hand, with the penetration of this moisture in the fibers of the filters, the resistance of the mask against the passage of air increases, which gives the person a feeling of suffocation and heavy breathing.

To solve this problem, moisture-absorbers are used to keep the moisture inside the mask at a desirable and acceptable level, reduce the difficulty of breathing, and increase the uncomfortable temperature inside the mask. Absorbents can be materials from plant sources (natural polymers such as gum) or synthetic sources (synthetic polymers such as polyacrylate). These natural or synthetic adsorbents can adsorb and trap water molecules with a positive, negative, or inductive charge. A variety of hydrogels are widely used in food, diapers, contact lenses, etc. because they show attractive behaviors such as water absorption, swelling, permeability, viscoelasticity, transparency, and biocompatibility.

Sodium alginate (Alg): A linear polysaccharide and a copolymer isolated from brown algae. It is an inexpensive biopolymer available that has received much attention due to its biodegradability, hydrophilic properties, sensitivity to pH, and natural origin. Alg absorbs moisture in such a way that it is able to absorb 1.2 grams of water per gram of dry matter. Alg has been used as a strong and fast high-efficiency moisture absorber around the mask. Sodium alginate is injected as a gel into the tubes around the second layer of the mask, absorbing moisture and modulating it inside the mask. It also prevents moisture from penetrating the adhesive on the sides of the mask, and increases the durability and comfort of the mask ( )

Polyacrylonitrile (PAN): A type of organic, semi-crystalline polymer resin obtained by acrylonitrile polymerization. This monomer can be produced in different industrial methods. The polymer has different uses and is used to produce various products such as filter layers, hollow fibers for reverse osmosis, fabric fibers, and oxidized polyacrylonitrile (PAN) fibers. Improved PAN fibers in the inner layer of the patient's mouth or nose, which contain viruses or microbes, are used to absorb the breathing fluid particles that also have the ability to absorb some of the moisture in the air, with the help of Alg. This polymer can absorb moisture and liquids with an efficiency of 60 %vv and can absorb moisture up to 60% of its weight in the exposure to saturated moisture and at respiratory temperature, and then dries quickly when not using the mask. Acrylic fibers are well resistant to bacteria and insects and can effectively filtrate the air along with the main filter (third layer) against ordinary solvents, oils, fats, mineral acids, bases that are not very concentrated, neutral salts, and some acid salts. Polyacrylonitrile fibers also have good mechanical strength and can withstand tearing by 35 to 50 kg, thus greatly increasing the physical quality of the mask and protecting it from physical damage such as tears and holes. PAN fibers are interwoven in the form of warp and weft with specific pores for easy air passage and are used as a second layer in the mask. ( )

Konjac Glucomannan Oligosaccharide Kojic acid (KGOK): This compound is a natural additive that is also used in food and has strong antibacterial and antimicrobial properties. It also has excellent moisture retention properties. In the third layer, KGOK crystal masks are sprayed on the main filter to play an antibacterial-antimicrobial role in this invention. However, activated carbon can also be used along with these particles as a toxic gas remover. In addition to this property, these particles can help PAN fibers and sodium alginate gel to absorb moisture and completely regulate respiratory air ( ).

It should be noted that the inhalation moisture should not be less than 40% in order to avoid irritation, pain, or dissatisfaction in the nasal mucosa, so in this design, we used absorbents that due to the durability of the mask (3-4 hours), as well as the efficiency and speed of moisture absorption by absorbers can absorb 30-60% of moisture and provide a balanced air for breathing, so the moisture inside the mask varies between 40-70% and therefore not the feeling of suffocation nor does it cause pain in the mucous membranes.

Medical-Grade Acrylic Polymer Adhesive: In the invention of this mask, it was noted that in order to use the mask satisfactorily, which may remain on the face for a long time, it is important that the adhesive has a composition compatible with the skin and does not cause irritation and inflammation of the skin. Moreover, the mask is designed in such a way that it is not uncomfortable for the consumer while talking or sneezing, and finally, the mask can be easily removed without leaving any marks on the face and without causing the wearer unbearable pain. Today, pressure-sensitive adhesives used in medical skin-contact treatments are mostly made from medical-grade acrylic polymers because they are not irritating to the skin and when sweating, hot air, showering, and exercising they remain adhered to human skin. Although many adhesive compounds are known, very few of them have a completely satisfactory function on human skin.

This mask consists of four layers:

Layer 1: consists of a simple layer of spunbond fabric ( - Layer 1 – Section A) that around the mask in this layer is completely coated with medical-grade acrylic polymer adhesive and causes the mask to fully attach to the face ( - Layer 1 - Section B), which prevents the escape of unfiltered air from the edges of the mask or around the nose or while talking, sneezing, etc. Also, with full attach on the face and no need for a strap, the pain behind the ear caused by the mask strap, as well as inflamed lines caused by long-term use of the mask on the face no longer occurs. Moreover, the possibility of the mask falling from the face while talking, the nose coming out of the mask due to the movement of the mask, or its detachment due to accidental collision is completely eliminated. The chemical formulation of medical-grade acrylic adhesive: Acrylic pressure-sensitive adhesives are prepared from the polymerization of acrylic ester free radicals and other monomers containing functional groups. Three types of acrylate monomers have been used in the preparation of this copolymer. The synthesis method of this adhesive is shown in (medical-grade acrylic adhesive).

Layer 2: consists of a moisture-absorbing layer made of PAN fibers ( - Layer 2 - Section D), which is intertwined in the form of warp and weft with certain pores for easy air passage and absorbs moisture at a gentle speed over a long period of time. A tube has been installed around this adsorbent layer that is filled with Alg gel ( - Layer 2, Section C), which plays the role of absorbing moisture with high speed and efficiency in a short time and also prevents the penetration of moisture into the mask adhesive. This layer plays a major role in properly absorbing moisture and modulating a person's breathing air. PAN fibers (second layer) also have the ability to help better air filtration along with polypropylene fibers (third layer). In addition to these properties, the strong structure of these fibers causes the physical strength of the mask and prevents tears or holes in it, and thus, along with the full adhesion of the mask to the face, creates a completely isolated and safe environment in the mask.

Chemical formulation of sodium alginate (Alg): Alg is a linear polysaccharide and a copolymer isolated from brown algae. It is an inexpensive biopolymer available that has received much attention due to its biodegradability, hydrophilic properties, sensitivity to pH, and natural origin. The synthesis method of this polymer can be seen in (Alg).

Chemical formulation of polyacrylonitrile (PAN): Polyacrylonitrile or acrylic (PAN) is a synthetic organic semi-crystalline polymer with linear formula (C3H3N)n. Polyacrylonitrile monomer is composed of vinyl cyanide or acrylonitrile. The synthesis method of this polymer is shown in (PAN).

Layer 3: consists of a polypropylene (melt blown) layer that filtrates virus-bacteria and other particles and contaminants ( - Layer 3 - Section F), which plays the role of the main filter of the mask. KGOK crystalline particles have been sprayed on this layer ( - Layer 3 - Section E), which creates a strong antibacterial-antimicrobial property in the mask and also helps to modulate the breathing air inside the mask along with the second layer absorbers by having the property of absorbing moisture.

Chemical formulation of Konjac Glucomannan Oligosaccharide Kojic acid (KGOK): is a polymeric compound produced by the synthesis of the monomers of Konjac Glucomannan Oligosaccharide using kojic acid. The synthesis method of this polymer is shown in (KGOK).

Layer 4: similar to the first layer, it consists of a simple layer of spun-bond fabric ( - Layer 4 - Section G) on which several folds ( - Layer 4 of Section H) are applied (following this layer, in other layers, several folds are also used), which has increased the functional area of the mask. Therefore, during the movement of the jaw and facial muscles while talking, sneezing, etc., the folds are opened, leading to the increased area of the mask, complete coverage of the face, and preventing the mask from detaching.

The amount of the four above-mentioned polymers used in the structure of the mask layers is as follows:

In the first layer, 3-5 grams of acrylic polymer adhesive is applied around the mask.

In the second layer, 25-30 grams of PAN fibers are used and 30-35 grams of Alg polymer are injected into the tube.

In the third layer, 7-10 grams of KGOK polymer are sprayed on the filter.

It should be noted that the purpose of this invention is not to produce moisture-absorbing polymers but to use the appropriate types of polymers available in the market to produce an efficient mask. For this purpose, we use polymers that are produced in the market and can be easily prepared. The amount of raw materials for the synthesis of these products has nothing to do with the subject of this invention and our basis is the amount of polymer used in different layers. However, the formulation and synthesis method of these polymers are presented in the map file only for further understanding of them.

Overall, the use of moisture-absorbing materials, as well as the quite strong adhesive with antibacterial-antimicrobial properties, facilitate the use of the mask for people and increases the durability of the mask. Moreover, with a greater desire to use the mask on the face against air pollution, it can provide complete health and safety.

According to the design of this invention, providing all the necessary conditions, and ease of use, anybody can paste the mask adhesive (as shown in ) and then press it on their face and easily use it. This mask can be used by all people in the community, including patients and healthy people in the age range of children to the elderly.

The use of mask by people in large and industrial cities with air pollution

The use of mask by the medical staff, including nurses, physicians, and surgeons in health centers

The use of mask by patients to prevent the spread of the disease agent

The use of mask by researchers in medical, veterinary, chemical, industrial, and research laboratories

The use of mask by workers to protect against industrial and occupational pollutants

Claims

In this mask, by embedding three suitable moisture absorbents (Alg, PAN, KGOK), the exhaled moisture is absorbed up to 30-60% and provides the fully adjusted breathing air with a moisture content of 40-70%.
The mask of claim 1, wherein each gram of dry Alg polymer can absorb 1.2 grams of moisture.
The mask of claim 1, wherein the PAN polymer can absorb moisture and liquids with an efficiency of 60%ww, and in saturated humidity and respiratory temperature, it can absorb moisture up to 60% of its weight.
The mask of claim 1, wherein the active presence of the PAN absorbent effectively absorbs and retains contaminated particles of the respiratory aerosols.
PAN interlocked fibers perform double air filtration action along with the main filtration layer. PAN polymer fibers also strengthen the structure of the mask and increase its physical resistance against force by 35 to 50 kg.
The presence of KGOK polymer on the inner surface of the mask with antibacterial-antimicrobial properties disinfects the mask from contamination.
Complete attachment of the mask on the face without a strap using medical-grade acrylic adhesive prevents skin inflammation, pain behind the ears and nose, penetration of contaminants, air escape around the mask, and its movement and slipping on the face.