WO2022098795A1 - Équipement de protection personnelle anti-pathogènes - Google Patents

Équipement de protection personnelle anti-pathogènes Download PDF

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Publication number
WO2022098795A1
WO2022098795A1 PCT/US2021/057949 US2021057949W WO2022098795A1 WO 2022098795 A1 WO2022098795 A1 WO 2022098795A1 US 2021057949 W US2021057949 W US 2021057949W WO 2022098795 A1 WO2022098795 A1 WO 2022098795A1
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Prior art keywords
ppe
ros
oxidizer
photocatalyst
fabric
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PCT/US2021/057949
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English (en)
Inventor
Robert Meagley
Michael Rattner
Daniel Mccormick
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Advancedmems Llc
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Publication of WO2022098795A1 publication Critical patent/WO2022098795A1/fr

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/16—Disinfection, sterilisation or deodorisation of air using physical phenomena
    • A61L9/18—Radiation
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/16—Disinfection, sterilisation or deodorisation of air using physical phenomena
    • A61L9/18—Radiation
    • A61L9/20—Ultraviolet radiation
    • A61L9/205—Ultraviolet radiation using a photocatalyst or photosensitiser
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2209/00—Aspects relating to disinfection, sterilisation or deodorisation of air
    • A61L2209/10—Apparatus features
    • A61L2209/14—Filtering means
    • A—HUMAN NECESSITIES
    • A62—LIFE-SAVING; FIRE-FIGHTING
    • A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
    • A62B18/00—Breathing masks or helmets, e.g. affording protection against chemical agents or for use at high altitudes or incorporating a pump or compressor for reducing the inhalation effort
    • A62B18/02—Masks
    • A62B18/025—Halfmasks

Definitions

  • the present invention is related to personal protective equipment (PPE) and methods of manufacture thereof that enable PPE to catalytically destroy pathogens.
  • PPE personal protective equipment
  • Nonwoven microfiber is typically formed by extrusion of hot thermoplastic- through a small orifice (also known as spunbonding or melt blowing).
  • the PPE often takes the form of a facial mask to protect both the nose and mouth of the wearer from intrusion of pathogens.
  • the fibers comprising the PPE are typically sized and are grouped in a density such that when spunbonded the resulting material layers are rendered with correct pore sizing sufficient so that the final layers stack will mechanically filter particles and droplets as small as 0.3 microns and larger (nominally 0.3 micron or smaller pores).
  • the materials may be treated chemically to convey a surface charge to aid in attracting and/or binding particles and pathogens electrostatically, and/or to provide a disinfectant quality to the fiber surface.
  • Such treatment may comprise copper and/or other metals as salts, acids, bases and/or other compounds, and/or other chemical disinfectants/antimicrobials.
  • Such PPE may comprise multiple material layers which, in turn, may comprise different compositions to further improve efficiency, e.g., an acid-treated layer, metal salt-treated layer, base-treated layer, and or layers of different porosity and/or different spunbonded fiber compositions.
  • Disposable PPE for breathing air predominantly takes two forms: the N95 (N90, N99, etc.) type masks, and surgical type masks.
  • the N95 and related masks are differentiated by having a multi-layer construction, wherein an inner layer comprising smaller diameter fiber, called the “electret” layer, holds a net electric charge, and outer layers comprise larger diameter fiber. Both types of mask comprise microfiber materials where the fiber diameter is ⁇ 100 microns.
  • N95s typically comprise nonwoven microfibers
  • surgical masks can comprise either woven or nonwoven microfibers. While surgical masks are little more than layered fabric covering the nose and mouth and are capable of intercepting droplets and large particles, N95 face masks are specified to filter 95% of particles down to 0.3 microns, small enough to filter the majority of droplets that carry viruses and other pathogens from the air before they contact the user. N95 masks do not function as simple sieves.
  • An embodiment of the present invention is personal protective equipment (PPE) comprising a photocatalyst and an oxidizer capable of supplying triplet oxygen to the photocatalyst.
  • PPE personal protective equipment
  • the photocatalyst is optionally doped and/or optionally comprises one or more perovskites, engineered inverse opal nanostructures, or quantum dots.
  • the photocatalyst is preferably capable of enabling the production of one or more reactive oxygen species (ROS) when the photocatalyst is irradiated with electromagnetic radiation.
  • the electromagnetic radiation is optionally ultraviolet, near ultraviolet, or visible light.
  • the PPE optionally comprises a frame and a fabric, wherein the fabric comprises filter elements which are replaceable, recyclable, and/or biodegradable.
  • the frame optionally comprises a battery and at least one LED which produces the electromagnetic radiation.
  • the PPE optionally comprises a phosphorescent material which releases the electromagnetic radiation when the phosphorescent material is not being illuminated.
  • the ROS preferably comprises singlet oxygen.
  • the PPE preferably further comprises a moderator separating the photocatalyst from the oxidizer. Heat and/or moisture produced by a user of the PPE preferably alters a permeability of the moderator, thereby enabling a predetermined consumption rate of the oxidizer and a predetermined release rate of the ROS within a fabric of the PPE.
  • the moderator can be water soluble or gellable and is preferably selected from the group consisting of agar, microcrystalline cellulose, pectin, starch, poly(vinylpyrrolidone) (PVP), poly(vinylalcohol) (PVA), poly(ethyleneoxide), poly(ethyleneglycol) (PEG), and poly(acrylic acid).
  • the PPE preferably further comprises a scavenger for transforming the ROS into triplet oxygen before it reaches the user.
  • the scavenger is preferably selected from the group consisting of charcoal, clay, diatomite, diatomaceous earth, sodium sulfite, sodium bisulfite, sodium metabisulfate, hydroquinione, butylated hydroxytoluene (BHT), and molecular sieves.
  • the PPE preferably further comprises a binder for enhancing adhesion of the photocatalyst to fibers in a fabric comprising the PPE.
  • the binder is preferably selected from the group consisting of silica, silicone, siloxane, carbon, polydimethylsiloxane, tetraethyl orthosilicate (TEOS), tetraethoxysilane, mercaptopropyltriethoxysilane, (3-Aminopropyl)triethoxysilane (APTES), aminopropyltriethoxysilane, vinyltriethoxysilane, clay, bentonite, montmorillonite, and pillared clay.
  • TEOS tetraethyl orthosilicate
  • APTES 3-Aminopropyl)triethoxysilane
  • aminopropyltriethoxysilane vinyltriethoxysilane
  • clay bentonite, montmorillonite, and pillared clay.
  • the PPE optionally comprises one or more MEMS sensors for monitoring biological loads, particle loads, and/or generation of the ROS.
  • the PPE preferably comprises a mask.
  • the PPE optionally further comprises a material and a heat producing system, wherein the material is capable of enabling the production of one or more of the ROS when the material is heated to a predetermined temperature, preferably when the PPE is not illuminated.
  • the heat producing system optionally comprises components which are capable of undergoing an exothermic chemical reaction, or alternatively preferably comprises a power supply and thermoelectric heater.
  • the PPE may comprise a frame and a fabric, wherein the frame comprises the power supply and/or thermoelectric heater.
  • the material optionally comprises a thermocatalyst, which is preferably selected from the group consisting of metal oxyanions, metal salts of transition metal oxyanions, iron/carbon nanotubes, and carbon.
  • the material optionally comprises a hypochlorite, wherein a chemical reaction between the hypochlorite and the oxidizer produces ROS.
  • PPE personal protective equipment
  • the inverse opal structure is preferably two dimensional or three dimensional and preferably has a periodicity approximately equal to a wavelength of electromagnetic radiation which enables the photocatalyst to produce the ROS.
  • the inverse opal structure preferably comprises features which are between approximately 0.1 microns and approximately 0.5 microns, and more preferably between approximately 0.2 microns and approximately 0.4 microns, in size.
  • the inverse opal structure preferably comprises features which are periodically spaced between approximately 0.1 microns and approximately 0.5 microns, more preferably between approximately 0.2 microns and approximately 0.4 microns, apart.
  • the electromagnetic radiation is optionally ultraviolet, near ultraviolet, or visible light.
  • the PPE optionally comprises a frame and a fabric, wherein the fabric comprises filter elements which are replaceable, recyclable, and/or biodegradable.
  • the frame optionally comprises a battery and at least one LED which produces the electromagnetic radiation.
  • the PPE optionally further comprises a phosphorescent material which releases the electromagnetic radiation when the phosphorescent material is not being illuminated.
  • the photocatalyst preferably comprises submicron sized components, which are preferably selected from the group consisting of particles, rods, flakes, cubes, prisms, tubes, fuzz, fibers, shells, and wires. At least one of the dimensions of the components is preferably between approximately 0.05 microns and approximately 0.25 microns.
  • the PPE optionally comprises one or more MEMS sensors for monitoring biological loads, particle loads, and/or generation of the ROS.
  • the ROS preferably comprises singlet oxygen.
  • the PPE preferably comprises an oxidizer capable of supplying triplet oxygen to the photocatalyst.
  • Rule NaS2O8 benzoyl peroxide, superoxide, hydroperoxide, and tetrabutylhydroperoxide.
  • the PPE preferably further comprises a moderator separating the photocatalyst from the oxidizer.
  • Heat and/or moisture produced by a user of the PPE alters a permeability of the moderator, thereby enabling a predetermined consumption rate of the oxidizer and a predetermined release rate of the ROS within a fabric comprising the PPE.
  • the moderator is preferably selected from the group consisting of agar, microcrystalline cellulose, pectin, starch, poly(vinylpyrrolidone) (PVR), poly(vinylalcohol) (PVA), poly(ethyleneoxide), poly(ethyleneglycol) (PEG), and poly(acry lie acid).
  • the PPE preferably further comprises a scavenger for transforming the ROS into triplet oxygen before it reaches the user.
  • the scavenger is preferably selected from the group consisting of charcoal, clay, diatomite, diatomaceous earth, sodium sulfite, sodium bisulfite, sodium metabisulfate, hydroquinione, butylated hydroxytoluene (BHT), and molecular sieves.
  • the PPE preferably further comprises a binder for enhancing adhesion of the photocatalyst to fibers in a fabric comprising the PPE.
  • the binder is preferably selected from the group consisting of silica, silicone, siloxane, carbon, polydimethylsiloxane, tetraethyl orthosilicate (TEOS), tetraethoxysilane, mercaptopropyltriethoxysilane, (3"Aminopropyl)triethoxysilane (APTES), aminopropyltriethoxysilane, vinyltriethoxysilane, clay, bentonite, montmorillonite, and pillared clay.
  • TEOS tetraethyl orthosilicate
  • APTES tetraethoxysilane
  • aminopropyltriethoxysilane vinyltriethoxysilane
  • clay bentonite, montmorillonite, and pillared clay.
  • the PPE optionally further comprises a material and a heat producing system, wherein the material is capable of enabling the production of one or more of the ROS when the material is heated to a predetermined temperature, preferably when the PPE is not illuminated.
  • the heat producing system optionally comprises components which are capable of undergoing an exothermic chemical reaction, or alternatively preferably comprises a power supply and thermoelectric heater.
  • the PPE may comprise a frame and a fabric, wherein the frame comprises the power supply and/or thermoelectric heater.
  • the material optionally comprises a thermocatalyst, preferably selected from the group consisting of metal oxyanions, metal salts of transition metal oxyanions, iron/carbon nanotubes, and carbon.
  • the material alternatively optionally comprises a hypochlorite, wherein a chemical reaction between the hypochlorite and the oxidizer produces ROS.
  • the PPE preferably comprises a mask.
  • Another embodiment of the present invention is personal protective equipment (PPE) comprising a materia!; an oxidizer capable of supplying triplet oxygen to the material; and a heat producing system; wherein the material is capable of enabling the production of one or more reactive oxygen species (ROS) when the material is heated to a predetermined temperature, preferably when the PPE is not illuminated.
  • the heat producing system optionally comprises components which are capable of undergoing an exothermic chemical reaction, or alternatively preferably comprises a power supply and thermoelectric heater.
  • the PPE optionally comprises a frame and a fabric-, wherein the frame comprises the power supply and/or thermoelectric heater.
  • the material optionally comprises a thermocatalyst, which is preferably selected from the group consisting of metal oxyanions, metal salts of transition metal oxyanions, iron/carbon nanotubes, and carbon.
  • the PPE preferably further comprises a binder for enhancing adhesion of the thermocatalyst to fibers in a fabric comprising the PPE.
  • the binder is preferably selected from the group consisting of silica, silicone, siloxane, carbon, polydimethylsiloxane, tetraethyl orthosilicate (TEOS), tetraethoxysilane, mercaptopropyltriethoxysilane, (3- Aminopropyl)triethoxysilane (APTES), aminopropyltriethoxysilane, vinyltriethoxysilane, clay, bentonite, montmorillonite, and pillared day.
  • the material alternatively optionally comprises a hypochlorite, wherein a chemical reaction between the hypochlorite and the oxidizer produces the ROS, which preferably comprises singlet oxygen.
  • the PPE optionally further comprises a photocatalyst capable of enabling the production of one or more reactive oxygen species (ROS) when the photocatalyst is contacted by the triplet oxygen and is irradiated with electromagnetic radiation.
  • the photocatalyst is optionally doped and/or comprises one or more perovskites, engineered inverse opal nanostructures, or quantum dots.
  • the electromagnetic radiation is optionally ultraviolet, near ultraviolet, or visible light.
  • the PPE optionally comprises a frame and a fabric, wherein the fabric comprises filter elements which are replaceable, recyclable, and/or biodegradable.
  • the frame optionally comprises a battery and at least one LED which produces the electromagnetic radiation.
  • the PPE optionally further comprises a phosphorescent material which releases the electromagnetic radiation when the phosphorescent material is not being illuminated.
  • the PPE preferably further comprises a moderator separating the thermocatalyst from the oxidizer. Heat and/or moisture produced by a user of the PPE preferably alters a permeability of the moderator, thereby enabling a predetermined consumption rate of the oxidizer and a predetermined release rate of the ROS within a fabric of the PPE.
  • the moderator is optionally water soluble or gellable and is preferably selected from the group consisting of agar, microcrystalline cellulose, pectin, starch, polyvinylpyrrolidone) (PVP), poly(vinylalcohol) (PVA), poly(ethyleneoxide), poly(ethyleneglycol) (PEG), and poly(acrylic acid).
  • PVP polyvinylpyrrolidone
  • PVA poly(vinylalcohol)
  • PEG poly(ethyleneglycol)
  • acrylic acid poly(acrylic acid).
  • the PPE of claim 64 further comprising a scavenger for transforming the ROS into triplet oxygen before it reaches the user.
  • the scavenger is preferably selected from the group consisting of charcoal, clay, diatomite, diatomaceous earth, sodium sulfite, sodium bisulfite, sodium metabisulfate, hydroquinione, butylated hydroxytoluene (BHT), and molecular sieves.
  • the PPE optionally comprises one or more MEMS sensors for monitoring biological loads, particle loads, and/or generation of the ROS.
  • the PPE preferably comprises a mask.
  • PPE personal protective equipment
  • the material is capable of decomposing the oxidizer to create one or more reactive oxygen species (ROS) at ambient temperature and in the absence of illumination.
  • the ROS preferably comprises singlet oxygen.
  • the chemical oxidizer preferably comprises a peroxide or a hypochlorite salt.
  • the material preferably comprises water, a catalyst, a Fe l!i compound, a Mo vl , compound, a V v compound, or sodium molybdate.
  • FIGS. 1A-1F show AFM images of two sizes of self-assembled nitrogen-doped graphene shells on glass substrates forming an inverse opal structure.
  • FIG. 2 shows AFM and optical images of titania inverse opal structures.
  • Embodiments of the present invention are PRE that can destroy pathogens carried by air and drawn through the PRE
  • the terms “personal protective equipment” and “PPE” mean masks, surgical masks, N95 masks and respirators, gowns, bonnets and other disposable PPE, curtains, privacy screens, mosquito netting, bedding, garments, reusable respirators for civilian, health care, first responders and military, portable air purification units, HVAC filtration systems, chemical abatement for civilian and military applications, and the like.
  • the PPE may comprise materials such as polyolefin, polypropylene, polyethylene, saran, polyester, polylactic acid, dacron, rayon, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyacrylic, polyacrylonitrile, modacrylic, polycarbonate, polyether-polyurea copolymer, spandex, lycra, elastane, polyamide, nylon, aramid, kevlar, nomex, polybenzimidazole, polystyrene, polyurethane, PTFE, PVDF, cellulosic material, semi-synthetic cellulosic material, viscose, cellophane, cellulose nitrate, cellulose acetate, cotton, cotton polyester blend, or paper.
  • Non-woven fabrics used for the PPE may be manufactured by methods such as carding, air laying, wet laying, spunbonding, melt blowing, electrospinning, or felting.
  • the vehicle for applying one or more of the chemistries described below to the PPE fabric is preferably chosen for compatibility with the PPE, photoc-atalyst, dopant and binder such that the vehicle does not degrade their performance.
  • the vehicle may comprise a pure substance or a mixture such as water, anhydrous solvent, water, acetic acid, isopropanol, acetone, methylethylketone, ethyl acetate, toluene, xylene, carrier gas, nitrogen, argon, anhydrous air, and air.
  • the treatment may be blended prior to application to the PPE and applied using standard PPE processing and equipment as a constituent of the materials used to fabricate the PPE.
  • Vapor phase methods such as chemical vapor deposition, plasma enhanced chemical vapor deposition, or liquid phase processing such as spraying, electrospraying, pneumatic spraying, and immersion may be employed.
  • the treatment is preferably introduced as a constituent of the materials used to fabricate the PPE; for example, the treatment can be added to precursors used to form PRE fibers, or tho treatment can be applied io nonwoven webs prior to final bonding.
  • the PRE of the present invention can incorporate RFIDs to verify the PPE and to track their usage and lifetime.
  • MEMS sensors potentially integrated via RFID, can track bio and particle loads and monitor reactive oxygen species (ROS) generation.
  • a mask of the present invention may comprise a mask frame with replaceable filter elements. By powering the frame, additional methods of ROS generation may be realized per the descriptions below.
  • PPE of the present invention may be more environmentally friendly by using recyclable or biodegradable mask materials such as Poly(hydroxybutyrate-co-hydroxyvalerate) or Chitosan (D-glucosamine and N- acetyl-D ⁇ glucosamine).
  • Singlet oxygen is a highly effective antipathogenic gaseous disinfectant that quickly decays to form other ROS, such as hydroxyl radical anions (from reaction with water vapor), ozone (O3, from reaction with oxygen), and nitroxide (from reaction with nitrogen), which in turn are also highly effective disinfectants.
  • the path length for this complete transition is nominally 1 mm.
  • a low energy oxidizer can be decomposed using a light-activated large band gap metal oxide to make ROS.
  • the photocatalyst may be activated with light such as visible light, ambient light, fluorescent lighting, LED lighting, sunlight, ultraviolet light, mercury vapor light, or 450nm LEDs.
  • pure titania has a band gap of 3.4-3.6 eV. It absorbs and is activated predominantly by near-UV light in a single photon process. When irradiated with UV light, UV-induced electron-hole pairs are formed in the titania and diffuse to the titania surface. Surface reaction with oxygen is believed to proceed by electron capture, forming superoxide radical anions which are oxidized by a nearby hole to yield singlet oxygen. Thus titania produces reactive singlet oxygen by converting ordinary ground-state, triplet oxygen, 3 Oa, with 2 unpaired electrons, to the excited state singlet oxygen, '02, with paired electrons.
  • the oxygen source can be air or higher energy examples like hydrogen peroxide.
  • titania may be doped or combined with advanced photocatalysts such as perovskites, engineered inverse opal structures (described more fully below), and quantum dels. This will enable the modified photocatalyst to utilize longer wavelengths in the visible spectrum, allowing for effective ROS generation in a wider variety of environments.
  • advanced photocatalysts such as perovskites, engineered inverse opal structures (described more fully below), and quantum dels.
  • the outer layer of a woven or nonwoven fiber PRE mask or other PRE article preferably comprises an oxidizer and photocatalyst that form a photo-driven reactive oxygen species (ROS) generation system. These are preferably deposited, bonded, or layered upon the material of the outermost surface of the mask, away from the wearer.
  • the oxidizer preferably supplies triplet oxygen fo the photocatalyst, enabling high concentrations of oxygen or other species that react photocatalytically to form strong gaseous disinfectants such as singlet oxygen. When not illuminated, the oxidizer and photocatalyst preferably do not react.
  • the photocatalyst When illuminated, the photocatalyst preferably acts upon the triplet oxygen to produce ROS, which are typically effective gaseous disinfectants with a limited lifespan in humid air.
  • the ROS preferably disinfect the fibers and spaces between the fibers of the mask, sterilizing the material and particulates entrained within and passing through. This preferably provides an active, standoff antipathogenic effect to fundamentally improve the efficiency of the mask protection from viruses, bacferia, profisfs, cysts and fungi.
  • the dry moderator preferably separates the catalyst from the oxidizer, ensuring that they don’t mix during deposition and storage.
  • heat and moisture from breath preferably alter the permeability of the moderator, enabling the controlled release of ROS via the above described process.
  • the rate of oxidizer consumption is preferably controlled by the moderator to ensure approximately eight hours of chemically generated ROS disinfection; however, the present technology preferably enables the mask to continue to provide disinfecfion beyond the specified lifetime of eight hours by using purely atmospheric oxygen.
  • the moderator can also be used as a reaction trigger, or alternatively a break-seal can be used.
  • the trigger component preferably ensures the chemistry is stable and unreactive until the PRE is opened for use.
  • an optional scavenger which adsorbs and decomposes ROS back into ordinary oxygen before it can exit the respirator ensures the ROS do not contaminate breathing air.
  • the use of an oxidizer, moderator and scavenger with a photocatalyst preferably increases the rate at which the photocatalyst can generate ROS when compared to merely using ambient air alone as an oxidizer.
  • the present invention preferably overcomes the intrinsic limitations of unenhanced photocatalysis operating in ambient lighting by employing concentrated solid and gelled oxidizers to boost concentrations of oxygen available to the catalyst, increasing the rate and concentration of ROS produced, the stored chemical energy available from selected oxidizers, and the Gibbs’ free energy from both enthalpy and entropy to drive the ROS forming reaction.
  • the present improved catalytic system preferably enables oxidizer to react with lower activation energies. This unique system preferably remedies fundamental inefficiencies with existing photocatalytic mask technology by having multiple opportunities for engineering control, such as:
  • scavenger - the scavenger restricts the diffusion of ROS only to the parts of the mask requiring active pathogen control. Within about 0.5-1 mm of the generation site the ROS decompose back to oxygen, presenting no risk to the user of the PRE, especially mask wearers. This technology enables disinfection at up to that distance from the point of photocatalysis, which distance is significantly larger than the pore size typically found in PRE.
  • Methods for integrating photocatalyst materials to different process techniques include spraying (post- and mid- production), spunbonding/melt blowing (mid-production), electrospinning (alternate fine fiber spinning method, perhaps best for inner layers used in mid-production, e.g., prefilter and electret layer), dip coating (post- and mid-production), CVD/PECVD (post- and mid-production, typically limited in chemistry to volatile precursors, and pelletization of raws (pre-production; this would be addition of photocatalyst to raw plastic used to prepare the pellets input to spunbonding and melt blowing unit processes).
  • catalyst precursors include but are not limited to nanoparticles (including cubes, spheroids, plates, fibers/wires, tubes) and sol gels (formed from metal salts comprising chlorides, bromides, iodides, carbonates, acetates and nitrates), metal alkoxides (e.g. titanium alkoxides such as polybutyl titanate, Ti(OiPr)2, Ti(OBu)4, Ti(OCH(CH3)2)4, titanium isopropoxide, TiOEt 4 , and titanium ethoxide), and metal alkalides (e.g., Zn(OiPr) 2 , Zn(Et) 2 ).
  • metal alkoxides e.g. titanium alkoxides such as polybutyl titanate, Ti(OiPr)2, Ti(OBu)4, Ti(OCH(CH3)2)4, titanium isopropoxide, TiOEt 4 , and titanium ethoxide
  • metal alkalides e
  • catalyst precursors include but are not limited to metal halides comprising chlorides, bromides, iodides; metal alkoxides comprising lower molecular weight species (e.g. Ti(OiPr)2), and metal alkalides (e.g., Zn(OiPr) 2 , Zn(Et) 2 ).
  • Dopants may comprise metal fluorides formed from precursors comprising, for example, HF or ammonium fluoride, or halogens comprising, for example, HBr, Br 2 , HCI, Cl 2 , HI, os S 2 .
  • Dopants additives to enhance the activity of the photocatalyst, for example by increasing the photocatalysts light sensitivity
  • the photocatalyst can be doped prior to or in conjunction with deposition of the photocatalyst on the PPE fabric.
  • Oxidizers include but are not limited to calcium hypochlorite, peroxides such as H 2 O 2 (liquid), urea-H 2 O 2 complex (solid), KHSOs (aka Oxone), or benzoyl peroxide (solid), or hydroperoxides such as TBHP (tetrabutylhydroperoxide, liquid).
  • Moderators include but are not limited to water soluble or gellable materials such as agar, microcrystalline cellulose, pectin, starch, poiy(vinylpyrroiidone), poly(vinylalcohol), poly(ethyleneoxide), poly(ethyleneglycol), and poly(acrylic acid).
  • scavengers include but are not limited to charcoal, clay, diatomite/diatomaceous earth, sodium sulfite, sodium bisulfite, sodium meta bisulfate, hydroquinione, BHT and molecular sieves.
  • An optional binder preferably provides compliant support for the catalyst or photocatalyst, relieves strain, provides coating adhesion, prevents flaking, reduces dust generation, and reduces the mismatch of compliance and surface energy between inorganic films and organic fibers to enhance the integration of the chemistry with the PPE material.
  • the binder may be applied as a solid, liquid or gel (including a solgel) before or after the photocatalyst is deposited, or the binder may be formulated and deposited together with the photocatalyst.
  • the binder may comprise, for example, silica, silicone, polydimethylsiloxane, TEOS, tetraethoxysilane, mercaptopropyltriethoxysilane, APTES, aminopropyltriethoxysilane, vinyltriethoxysilane, clay, bentonite, montmorillonite, or pillared clay.
  • Table 1 is a list of examples of potential materials for use with the present invention.
  • a surgical mask formed from nonwoven semisynthetic paper fiber equilibrated for one hour in moist air (RH -70%) was exposed to chemical vapor treatment formed from titanium isopropoxide (Sigma) heated to above 45°C in dry air via a current of dry air impinging upon the outer surface of the mask until a visibie white residue of bound titanium dioxide was observed.
  • the mask was then gently tapped to mechanically dislodge any stray particles and was donned by the user.
  • Spraying was accomplished using a Nordson EFD 781S sprayer controlled with a Nordson EFD Valvemate 4080 controller equipped with a New Era Pump Systems NE1G00 syringe pump and 10ml disposable syringe connected to the sprayer with PEEK tubing and polyethylene fittings.
  • Spraying was performed at 15psi spray pressure and 40 psi lift pressure in 1 second bursts followed by 4 second quiescent intervals while the mask was repositioned in order that the front (outer) curved surface be evenly and completely treated over a total of 8 minutes at a treatment flow rate of 0.25 ml per minute while the mask was heated in warm (110 degrees Celsius) air.
  • the swatch was then heated in warm air for an additional 30 minutes after spraying, gently shaken to mechanically dislodge any stray particles, and used directly for the fabrication of the outermost layer of a mask such that the illuminated side was the treated side of the original swatch.
  • the interaction of light with a photocatalyst can be improved by shaping the photocatalyst and/or its supporting structure in a way to increase the amount of interaction time of light with the photocatalyst.
  • nanostructures having a size on the order of the light wavelength slow the light down as it interacts with the photocatalyst to improve efficiency of the system.
  • This “slow light” technology is broadly applicable to any system using a photocatalyst and light with an oxidizer (either atmospheric oxygen or with the technologies described in the embodiment above). This is an improvement over existing masks, which are restricted in their ability to generate ROS due to the low concentration of oxygen in air, the short interaction time for light with the photocatalyst, and the requirement for high intensity light and a long light exposure time.
  • slow light technology can increase the rate at which a photocatalyst can generate ROS over using a chemically identical photocatalyst that does not incorporate such light-wavelength- scaled periodic nanostructures. This is a method that can improve the efficiency of any photocatalytic system applied to photocatalytic mask technology.
  • the nanostructures preferably comprise inverse opal 2-D and 3-D gratings.
  • An inverse opal is a nanostructure where periodic- uniform void spaces are engineered within a material. When the dimension of the spaces is on the size scale of the wavelength of the incident light, the speed of light slows down for wavelengths approaching resonance with the system. By stowing the light, more time is allowed for light to interact with the photocatalytic material which increases efficiency. This technology may be applied to the photo catalysts described above.
  • preformed nanoscale 2-D, 1-D and 0- D photocatalytic materials e.g. flakes, cubes, prisms, rods, wires, or particles
  • precursors that form these materials can be deposited on fibers or a nanoporous membrane in combination with sacrificial nanoparticles sized to match the pore size required to produce the slow light effect.
  • voids of controlled size remain within the photocatalyst material. Processing conditions are preferably adjusted to ensure regular spacing of the voids.
  • gratings may comprise coatings of graphene, titania, other metal oxides, or the other photocatalysts described above, comprising for example nanoscale 2-D, 1-D and 0-D materials (e.g., flakes, cubes, prisms, rods, wires, particles), deposited on fibers previously textured with periodic structures (e.g. lines, holes, or posts) with a repeat period and dimension on the order of the desired wavelength of light.
  • nanoscale 2-D, 1-D and 0-D materials e.g., flakes, cubes, prisms, rods, wires, particles
  • periodic structures e.g. lines, holes, or posts
  • polystyrene spheres with a surface COOH function may be dissolved in a precursor solution or photocatalyst suspension, which is then coated on fibers or a membrane to form a self-assembled nanocomposite.
  • the sacrificial nanoparticles are dissolved with solvent to render an inverse opal catalytic coating.
  • this process may be performed stepwise, with coating and drying of the sacrificial nanoparticles, followed by coating (’’infiltration”) and drying of the photocatalyst, followed by removal of the sacrificial particles using a solvent and drying.
  • heat may be used to remove the sacrificial material by thermal decomposition (thermolysis), thus creating the inverse opal.
  • thermal decomposition thermal decomposition
  • polystyrene nanospheres decompose to gasses when heated over 175 degrees Celsius, and polyimide nanofibers are heat stable in the absence of oxygen to over 400 degrees Celsius
  • polyimide fibers coated with a TiCh-polystyrene microsphere nanocomposite can be heated in a nitrogen atmosphere to over 250°C for 10 minutes to remove the sacrificial polystyrene.
  • a polypropylene spunbond nonwoven fiber mat (preferably having fibers approximately 20 micron to 50 microns in diameter) was spray coated with a thin (preferably approximately 0.1 to 1 micron, more preferably approximately 0.5 microns, thick) layer of polybutyl titanate and nitrogen-doped graphene nanoparticles (preferably approximately 0.05 to 0.25 microns in size), as a blend with carboxylate functionalized polystyrene nanoparticles (preferably approximately 0.1 to 0.5 microns, more preferably approximately 0.2 to 0.4 microns, in size) preferably as a 20% suspension in 91% isopropyl alcohol, also comprising as an adhesion promoter 1% 3-aminopropyltriethoxysilane (APTES).
  • APTES 3-aminopropyltriethoxysilane
  • the deposit was dried at 10G°C for 10 minutes in air with 50% relative humidity (RH), followed by washing with toluene and acetone to coat the nonwoven microfiber material with photocatalytic TiOz/nitrogen-doped graphene to create the “slow light” effect.
  • Inverse opals have also been manufactured in this way on glass with 0-D T1O2 and 2-D CsPbBra nanoparticles formed from precursors in situ, using preformed TIOz and graphene nanoflakes to make near infrared (NIR) reflective devices.
  • a polypropylene spunbond nonwoven fiber mat (preferably comprising fibers approximately 20 microns to 50 microns in size) is spray coated with a thin (preferably approximately 0.1 to 1 micron, more preferably 0.5 microns, thick) layer of TIOz and nitrogen-doped graphene nanoparticles (preferably approximately 0.05 to 0.25 microns in size), then embossed by a warm (preferably between approximately 25“C and 160° C, the melting point of PP) roller comprising a pattern of lines and spaces (lines and spaces preferably approximately 0.15 to 0.5 microns wide, preferably regularly spaced approximafely 0.15 to 0.5 microns apart, preferably having a pitch from approximately 1 :3 to 3:1 , more preferably 1 :1), resulting in a nonwoven mat comprising a photocatalytic “slow light” grating structure.
  • a warm (preferably between approximately 25“C and 160° C, the melting point of PP) roller comprising a pattern of lines and spaces (lines and spaces
  • Analogous structures have been manufactured using preformed 1-D micro gratings with TIOz and CsPbBrs deposited upon them from precursors in situ and using preformed graphene nanoflakes and aluminum nanoparticles to make NIR reflective chemical sensors.
  • fibers or a nanoporous membrane preferably comprise inverse opal bubbles along the length of fiber or within the material of the membrane, insoluble fibers, such as polypropylene, preferably comprise soluble nanoparticles such as polystyrene, which after coating (such as via melt blow extrusion) are preferably removed with solvent such as toluene or acetone.
  • metamaterial opals preferably comprise “nanofuzz” (e.g. titania nanotubes or dendritic nanofibers) deposited on microfiber.
  • nanofuzz e.g. titania nanotubes or dendritic nanofibers
  • plastic microfibers are preferably sputtered with titanium metal, then anodized and oxidized to form titanium dioxide nanotube arrays preferably having dimensions on the order of the light wavelength.
  • the photocatalytic performance can be enhanced by adding illumination mechanisms fo the system, for example incorporating phosphorescent materials (e.g. silver or copper doped zinc sulfide, or Eu 2+ or Dy 3+ doped strontium aluminate) that store and release light energy in the dark after exposure to light, or by using a battery + blue (450nm), purple (405nm) or near UV (397nm) LED light sources.
  • phosphorescent materials e.g. silver or copper doped zinc sulfide, or Eu 2+ or Dy 3+ doped strontium aluminate
  • a battery + blue (450nm), purple (405nm) or near UV (397nm) LED light sources e.g. silver or copper doped zinc sulfide, or Eu 2+ or Dy 3+ doped strontium aluminate
  • self-assembled nitrogen-doped graphene inverse opal shells were formed by establishing an ionic bond between a basic amine functionalized nanoflake and an acid functionalized template in suspension. These self-assembled shell-covered templates were then deposited, and the template was removed.
  • the template size defined the critical dimension of the void space and the selfassembly conditions (chemical concentrations and process parameters) defined the wall thickness.
  • Freshly prepared aminopropylsilyl-functionalized graphene flakes were resuspended in 2ml 99% isopropyl alcohol by sonication as above, then treated with sacrificial carboxylate-functionalized polystyrene (latex) nano-spheres, either 0.42 micron or 1 micron in size (1 ml as a 10% suspension in water, in 200 microliter portions), which caused the graphene derivative and latex to precipitate as a diffuse rubbery material. This was resuspended by sonication, yielding a black suspension with a tendency to precipitate.
  • latex carboxylate-functionalized polystyrene
  • the freshly prepared aminopropylsilyl-functionalized graphene flake carboxylate-functionalized polystyrene nanocomposite suspension was dropcast on a glass microscope slide, evaporated to dryness forming a thin film opal, then calcinated at 250 degrees Celsius in a tube furnace to remove the polystyrene latex template via pyrolysis.
  • the thin film opal was cured at 50-100 degrees Celsius for approximately one hour in air, and a solvent wash with acetone and/or toluene was used to remove the template.
  • the resulting inverse opal is a foam comprising dense packed spherical shells with controlled diameter and wall thickness and was characterized by tapping mode atomic force microscopy (AFM), as shown in FIGS. 1A-1F.
  • FIG, 1A shows 1 micron inner hollow, 0.2 micron wall thickness shells which form the inverse opal.
  • FIGS. 1 B and 1 C are two AFM views at different magnifications of 0.4 micron inner hollow, 0.2 micron wall thickness shells which form the inverse opai.
  • FiGS. 1 D-1 F show the same images respectively but contrast is enhanced to better see structural detaiis.
  • the functionalized template was deposited first, then a liquid precursor was added which self-assembled the shell around the functionalized template by chelation of the precursor on the template.
  • the template size defined the critical dimension of the void space and the self-assembly conditions (chemical concentrations and process parameters) defined the wall thickness.
  • an isopropanol suspension (1 % solids, 90% isopropanol) of carboxy late- functionalized polystyrene latex was spin coated (500 RPM, 30 seconds) on a glass microscope slide and evaporated to dryness in air, forming a thin film opal.
  • the freshly prepared carboxylate-functionalized polystyrene opal was treated with a freshly prepared 5% solution of polybutyl titanate in 99% isopropanol (9.2 ml), spin coated, and evaporated to dryness. Ligands and solvent were then removed to form titania by heating on a 100°C hotplate for 15 minutes.
  • the polystyrene latex template was removed by washing with toluene (1 minute irrigation with 5 ml portionwise with a pipette), then calcinated at 250 G C on a hot plate to remove polystyrene and toluene residue and produce an anatase/rutile mixed crystal structure in the titania.
  • the thin film opal was cured at 50- 100 G C for approximately one hour in air, and a solvent wash with acetone and/or toluene was used to remove the template.
  • the resulting titania inverse opal foam comprised dense packed spherical shells with controlled diameter and wall thickness and was characterized visually to compare reflected versus transmitted light, confirming the presence of an optical band gap, which is characteristic of the desired nanostructure. Further characterization was performed by tapping mode AFM and optical microscopy, as shown in FIG. 2. As shown in FIG. 2, the images are clockwise from top left: photograph of reflectance showing orange color from the photonic band-gap centered at ⁇ 560nm; photograph of blue transmittance; AFM image of 0.5 micron inner hollow, 0.26 micron wall thickness shells forming the inverse opal; and optical microscopy showing blue-green transmission.
  • thermocatalytic instead of photocatalysis, a thermally driven catalytic (i.e. thermocatalytic) system can be used, even at room temperature, for PRE ROS generation in darkness or low light levels, conditions in which photocatalytic systems cannot operate.
  • the system can be sprayed on, or dipped, post- and mid- process.
  • Most of the engineering controls from the above embodiments remain, except for the first control and substituting a thermal catalyst for the photocatalyst in the second control, while an additional control is preferably temperature of operation, such as produced by using a power supply and heater or an exothermic chemical reaction.
  • Heat may be used to control ROS generation, such as heat produced by a thermochemical or battery-operated thermoelectric heating unit.
  • Thermal catalysts include those that decompose oxidizers to form singlet oxygen or other ROS in the absence of light, such as metal oxyanions (metal salts of certain transition metal oxyanions, for example those comprising vanadate, molybdate (sodium molybdate), and tungstate), iron/carbon nanotubes (such as iron oxide (FezOs) encased in carbon nanotubes), and carbon (such as activated charcoal in the case of hydrogen peroxide and potentially other peroxides and hydroperoxides).
  • metal oxyanions metal salts of certain transition metal oxyanions, for example those comprising vanadate, molybdate (sodium molybdate), and tungstate
  • iron/carbon nanotubes such as iron oxide (FezOs) encased in carbon nanotubes
  • carbon such as activated charcoal in the case of hydrogen peroxide and
  • hypochlorite In the place of a catalyst, hypochlorite maybe used. While not catalytic, the reaction of stoichiometric hypochlorite (e.g. Ca(OCI)2, NaOCI) with solid, liquid or gelled oxidizer, for example a hydrogen peroxide or hydroperoxide oxidizer, forms singlet oxygen and ROS in the absence of light. Oxidizers and scavengers can be the same as those listed above.
  • stoichiometric hypochlorite e.g. Ca(OCI)2, NaOCI
  • solid, liquid or gelled oxidizer for example a hydrogen peroxide or hydroperoxide oxidizer
  • Singlet oxygen may alternatively be formed using chemical systems that operate in the absence of light.
  • the chemical system preferably results in the decomposition of an oxidizer with the production of singlet oxygen ( 1 O 2 .)
  • These systems preferably comprise chemical oxidizers and catalysts, and may operate at ambient or optionally elevated temperatures (i.e., thermocatalytic operation).
  • the oxidizer may comprise a peroxide-containing chemical, preferably hydrogen peroxide.
  • Additional oxidizers may comprise hypochlorite salts, for example sodium hypochlorite and calcium hypochlorite.
  • Catalysts include but are not limited to water, Fe Hi , Mo vl , or V v compounds, or sodium molybdate.

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Abstract

L'invention concerne un équipement de protection personnelle anti-pathogènes (PPE), tel que des masques, et des procédés de fabrication correspondants. L'équipement PPE peut comprendre un oxydant qui permet à un catalyseur de produire plus d'espèces réactives de l'oxygène (ERO) que lorsque seul l'air est utilisé, permettant ainsi d'augmenter la puissance de désinfection de l'équipement PPE. Le catalyseur peut être un photocatalyseur qui génère des espèces réactives de l'oxygène lorsqu'il est éclairé, qui peut être complété par des diodes électroluminescentes ou un matériau phosphorescent. Le photocatalyseur peut se présenter sous la forme d'une structure opale inversée pour maximiser le contact de la lumière avec le photocatalyseur. Le catalyseur pourrait être un catalyseur thermique qui génère des espèces réactives de l'oxygène lorsqu'il est chauffé, cela pouvant être complété par un dispositif de chauffage. En variante, un produit chimique peut être utilisé qui réagit avec l'oxydant pour générer des espèces réactives de l'oxygène dans l'obscurité et à des températures ambiantes. Des combinaisons de ces espèces réactives de l'oxygène permettent de générer des espèces réactives de l'oxygène dans n'importe quelles conditions.
PCT/US2021/057949 2020-11-03 2021-11-03 Équipement de protection personnelle anti-pathogènes WO2022098795A1 (fr)

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Cited By (1)

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DE202022105877U1 (de) 2022-10-19 2022-11-07 Biswaranjan Acharya System für persönliche Schutzausrüstung (PPE) mit Klima- und Lüftungsanlage

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WO2011116236A2 (fr) * 2010-03-18 2011-09-22 Blacklight Power, Inc. Système électrique électrochimique à catalyseur d'hydrogène
US20110250424A1 (en) * 2007-07-17 2011-10-13 Lombardi John L Pathogen-Resistant Fabrics
US20160001108A1 (en) * 2014-07-03 2016-01-07 Ling Zhou Breathing apparatus with ultraviolet light emitting diode
US20170275472A1 (en) * 2014-09-19 2017-09-28 The Hong Kong University Of Science And Technology Antimicrobial coating for long-term disinfection of surfaces
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US20060218853A1 (en) * 2003-05-10 2006-10-05 Mi-Hye Oh Composition for preventing scaling, excluding of soot, clinker and sludge, and controlling flame in combustion apparatus
US20110250424A1 (en) * 2007-07-17 2011-10-13 Lombardi John L Pathogen-Resistant Fabrics
WO2011116236A2 (fr) * 2010-03-18 2011-09-22 Blacklight Power, Inc. Système électrique électrochimique à catalyseur d'hydrogène
US20160001108A1 (en) * 2014-07-03 2016-01-07 Ling Zhou Breathing apparatus with ultraviolet light emitting diode
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US20200254432A1 (en) * 2017-09-29 2020-08-13 President And Fellows Of Harvard College Enhanced catalytic materials with partially embedded catalytic nanoparticles

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202022105877U1 (de) 2022-10-19 2022-11-07 Biswaranjan Acharya System für persönliche Schutzausrüstung (PPE) mit Klima- und Lüftungsanlage

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