WO2023056562A1 - Masques chirurgicaux/médicaux jetables et compostables et leurs procédés de production - Google Patents

Masques chirurgicaux/médicaux jetables et compostables et leurs procédés de production Download PDF

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Publication number
WO2023056562A1
WO2023056562A1 PCT/CA2022/051483 CA2022051483W WO2023056562A1 WO 2023056562 A1 WO2023056562 A1 WO 2023056562A1 CA 2022051483 W CA2022051483 W CA 2022051483W WO 2023056562 A1 WO2023056562 A1 WO 2023056562A1
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WIPO (PCT)
Prior art keywords
textile
pla
compostable
ply
disposable
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PCT/CA2022/051483
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English (en)
Inventor
David Dyck
Kyle FIOLKA
Travis Klassen
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Precision Adm Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Precision Adm Inc. filed Critical Precision Adm Inc.
Priority to CA3195532A priority Critical patent/CA3195532A1/fr
Publication of WO2023056562A1 publication Critical patent/WO2023056562A1/fr

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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
    • A41D13/1107—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape
    • A41D13/1115—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a horizontal pleated pocket

Definitions

  • This disclosure generally relates to disposable surgical/medical masks. More specifically, this disclosure pertains to disposable, compostable 3-ply surgical/medical soft masks and to methods, equipment, and systems for producing the masks.
  • ASTM Level 1 surgical/medical masks are rated as having low fluid resistance (resistance of the mask to penetration of a small volume of fluid at a high velocity) of 80 mmhg, a bacterial filtration efficiency (BFE) of > 95% and a 0.1-micron particulate filtration efficiency (PFE) of > 95%, and a breathability differential pressure (delta P) of ⁇ 4.0 mm F /cm 3 (as the DP value increases, the less the breathability or ease of breathing, but the better the filtration).
  • BFE bacterial filtration efficiency
  • PFE 0.1-micron particulate filtration efficiency
  • delta P breathability differential pressure
  • ASTM Level 2 surgical/medical masks are rated as having moderate fluid resistance of 120 mmhg, a BFE of > 98% and PFE of > 98%, and a breathability delta P of ⁇ 5.0 mm F /cm 3 .
  • ASTM Level 3 surgical/medical masks are rated as having high fluid resistance of 160 mmhg, a BFE of > 98% and PFE of > 98%, and a breathability delta P of ⁇ 5.0 mm F /cm 3 .
  • thermoplastic polymers commonly used to produce melt-blown textiles include polypropylene, polystyrene, polyesters, polyurethane, polyamides (nylons), polyethylene, polycarbonate, and the like.
  • Such disposable surgical/medical masks are typically manufactured by drawing out from spools or bobbins along a machine, a three-layered sheet having a middle layer of a selected textile with a top layer and a bottom layer of a selected non-woven textile.
  • the three-layered sheet is pleated then ultrasonically welded, then stamped with a deformable metal nose strip and a pair of elasticized ear loops that are ultrasonically welded to the mask.
  • the currently available surgical/medical masks are made with materials, that is metal strips, elasticized ear loops, and biodegradable-resistance textiles spun from thermoset polymers, that can only be safely disposed of and eliminated through incineration and then valorization.
  • the embodiments of the present disclosure generally relate to disposable, compostable surgical/medical masks comprising assemblies of a plurality of components wherein the components have been fashioned from polylactic acid (PLA) materials and polymeric resin materials.
  • PLA polylactic acid
  • One example embodiment relates to a disposable, compostable surgical/medical mask comprising (i) a 3-ply face-mask component wherein the two outer layers are a spunbond PLA textile and the third center layer is a meltblown PLA textile, (ii) a deformable nose bar formed from a PLA extrudate, and (iii) a pair of elongate narrow-width 3-ply stretchable soft ear loop strips wherein the two outer strips are spunbond PLA textile and the third middle layer is a compostable elastic polymeric resin film.
  • a pair of resilient elastic ear loops may be substituted for the pair of elongate narrow-width 3-ply stretchable soft ear loop strips.
  • the 3-ply face-mask component may be produced by concurrently unspooling a first spunbond PLA textile with a meltblown PLA textile and a second spunbond PLA textile to thereby form a 3-ply layered assembly that may then be pleated by pleating rollers and ultrasonically welded to form a laminated 3-ply facemask component.
  • a disposable, compostable surgical/medical mask comprising (i) a 4-ply face-mask component wherein the two outer layers are a spunbond PLA textile and the two middle layers are a meltblown PLA textile, (ii) a deformable nose bar formed from a PLA extrudate, and (iii) a pair of elongate narrow-width 3-ply stretchable soft ear loop strips wherein the two outer strips are spunbond PLA textile and the third middle layer is a compostable elastic polymeric resin film.
  • a pair of resilient elastic ear loops may be substituted for the pair of elongate narrow-width
  • a pair of resilient elastic ear loops may be substituted for the pair of elongate narrow-width 3-ply stretchable soft ear loop strips.
  • the 3-ply face-mask component may be produced by concurrently unspooling a first spunbond PLA textile with two meltblown PLA textiles and a second spunbond PLA textile to thereby form a 4-ply layered assembly that may then be pleated by pleating rollers and ultrasonically welded to form a laminated
  • the deformable nose bar may be produced by extrusion of an extrusiongrade PLA through an extruder fitted with a die with round bores therethrough to produce elongate solid round PLA bars or alternatively, through a die having elongate slits therethrough to produce solid rectangular PLA strips.
  • the solid round PLA bars may be corrugated.
  • the solid rectangular bars may be corrugated.
  • the deformable nose bar may be an aluminum strip.
  • the 3-ply soft ear loop strips may be produced by concurrently unspooling a first spunbond PLA textile with a first compostable elastic film and a second spunbond PLA textile to thereby form a 3-ply layered assembly that may then be bonded together by ultrasonic welding to produce an intermediate laminate textile.
  • the first and second PLA textiles may be meltblown PLA textiles.
  • the 3-ply layered assembly may be bonded together by passage through a hot-roll calendaring apparatus.
  • the 3-ply layered assembly may be bonded together by an adhesive bonding process.
  • the intermediate textile may then be activated by passage through one or more stages of rollers having circumferential grooves of generally rectangular or triangular form that closely mesh to thereby stretch the two outer inelastic layers and cause a permanent elongation in the laminated textile in the cross direction (CD) that does not exceed the elastic limit of the elastic film sandwiched between the two outer layers.
  • This elongation activates 3-ply laminated textile and provides soft resilience that enables the textile to be stretched and then return to its original shape in the cross direction (CD) while maintaining stiffness in the machine direction (MD).
  • the activated 3-ply stretchable textile may then be cut into elongate strips having a selected width, along the machine-direction axis of the activated 3-ply stretchable textile to thereby form 3-ply stretchable soft ear loop strips.
  • the disposable, compostable soft ear loop strips may comprise two layers of textile wherein one layer may be a spunbond PLA textile and the second layer may be a compostable elastic polymeric resin film.
  • the disposable, compostable soft ear loop strips may comprise four or more layers of heat-embossed textiles wherein are alternating layers of spunbond PLA textiles and compostable elastic polymeric resin films.
  • the disposable, compostable 3-ply surgical/medical masks disclosed herein may be assembled by ultrasonic welding the deformable PLA nose bar along one of the elongate edges of the laminated 3- ply face-mask component, then ultrasonically welding of the ends of a first.
  • 3-ply stretchable soft ear loop strip about the top and bottom of one side edge of the laminated 3-ply face-mask component, and then ultrasonically welding of the ends of a second.
  • 3-ply stretchable soft ear loop strip about the top and bottom of the opposite side edge of the laminated 3-ply face-mask component to thereby produce a disposable, compostable surgical/medical mask according to this disclosure.
  • each of a pair of resilient elastic ear loops may be electronically welded to the top and bottom edges of the laminated 3-ply facemask component.
  • the disposable, compostable 4-ply surgical/medical masks disclosed herein may be assembled by ultrasonic welding the deformable PLA nose bar along one of the elongate edges of the laminated 4- ply face-mask component, then ultrasonically welding of the ends of a first.
  • 3-ply stretchable soft ear loop strip about the top and bottom of one side edge of the laminated 3-ply face-mask component, and then ultrasonically welding of the ends of a second.
  • 3-ply stretchable soft ear loop strip about the top and bottom of the opposite side edge of the laminated 4-ply face-mask component to thereby produce a disposable, compostable surgical/medical mask according to this disclosure.
  • each of a pair of resilient elastic ear loops may be electronically welded to the top and bottom edges of the laminated 4-ply facemask component.
  • the disposable, compostable surgical/medical masks may comprise five layers of compostable textile layers in which case, the masks may be referred to as 5-ply disposable, compostable surgical/medical masks.
  • the intermediate layer or layers may comprise an electrospun PLA layer or layers.
  • FIG. 1 shows perspective exploded views of a disposable, compostable 3- ply mask according to an embodiment disclosed herein wherein FIG. 1 A is a front view of the three layers before pleating, and FIG. 1B is a front view of the three layers after pleating;
  • Fig. 2A is an outward-facing front view of an example embodiment of a disposable, compostable 3-ply mask disclosed herein;
  • FIG. 2B is an inward-facing back view of the mask shown in FIG. 2A;
  • FIG. 3A is a close-up front view of a side edge of the mask shown in FIG. 2B, showing a soft resilient ear loop component prior to use of the mask;
  • FIG. 3B is a close-up front view of the side edge after the ear loop component has been separated from the mask and activated for securing the mask to the individual’s face;
  • Fig. 4A is an inside back view of the mask shown in FIG. 2A, unfolded with the ear loops separated and deployed for mounting onto an individual’s face;
  • Fig. 4B is a front view of the unfolded mask shown in FIG. 4A;
  • FIG. 5 is a close-up front view of the side edge of the unfolded mask shown in FIG. 4B after the ear loop component has been separated from the mask;
  • FIG. 6 shows perspective exploded views of the disposable, compostable
  • FIG. 6A is a front view of the 3-ply mask provided with an elastic ear loop component
  • FIG. 6B is a front view of the 3- ply mask provided with a soft resilient ear loop component
  • FIG 7 shows perspective exploded views of a disposable, compostable 4- ply mask according to an embodiment disclosed herein wherein FIG. 7A is a front view of the four layers before pleating, and FIG. 7B is a front view of the four layers after pleating;
  • FIG. 8 shows perspective exploded views of the disposable, compostable
  • FIG. 8A is a front view of the 4-ply mask provided with an elastic ear loop component
  • FIG. 8B is a front view of the 4- ply mask provided with a soft resilient ear loop component
  • FIG. 9 provides an outward-facing front view (FIG. 9A) and an inwardfacing rear view (FIG. 9B) of the 4-ply mask provided with an elastic ear loop component shown in FIG. 8A, while FIG. 9C is an outward-facing front view and FIG. 9D is an inward- facing rear view of the 4-ply mask provided with a soft resilient ear loop component shown in FIG. 8B;
  • FIG. 10 shows a scanning electron microscope image of a meltblown textile according to an embodiment disclosed herein taken at a magnification of 250X (FIG. 10A) and at a magnification of 1000X (FIG. 10B);
  • FIG. 11 is a chart illustrating the pore distribution and polymer fiber diameter properties of an example single meltblown textile disclosed herein;
  • FIG. 12 is a chart illustrating the pore distribution and polymer fiber diameter properties of an example double meltblown textile disclosed herein;
  • FIG.13 is chart illustrating blood penetration correlation plots for an example single meltblown textile and an example double meltblown textile disclosed herein;
  • FIG. 14 is a chart illustrating multivariable correlation plots of the GSM and blood penetration performance characteristics of an example single meltblown textile
  • FIG. 15 is a chart illustrating multivariable correlation plots of the GSM and blood penetration performance characteristics of an example double meltblown textile.
  • FIG. 16 shows images taken after performance of a sessile drop test with artificial blood on meltblown textiles produced with four difference corona charge processes (FIGs 16A, 16B, 16C, 16D).
  • the embodiments of the present disclosure generally relate to disposable, compostable surgical/medical masks comprising assemblies of a plurality of components wherein each of the components has been fashioned from polylactic acid (PLA) materials.
  • PLA polylactic acid
  • FIGs. 1 to 6 An embodiment of an example of a disposable, compostable 3-ply surgical/medical mask 10 disclosed herein is shown in FIGs. 1 to 6.
  • the disposable, compostable surgical/medical mask 10 has an inward-facing outer layer 20 made from a spunbond PLA textile, an outward-facing outer layer 40 made from a spunbond PLA textile, a middle layer 30 made from a meltblown PLA textile sandwiched between the outward-facing and inward-facing layers 40, 20, and a deformable nosebar 35 formed from extruded PLA.
  • the compostable, disposable surgical/medical mask 10 may be referred to as a 3-ply compostable, disposable surgical/medical mask.
  • outward-facing and inward-facing spunbound textile layers 40, 20 may be considered to be and may be referred to as barrier layers. It is also to be noted that the middle meltblown PLA textile layer 30 may be considered to be and may be referred to as a filtration layer.
  • the deformable nose bar 35 may be produced by extrusion of an extrusiongrade PLA through an extruder fitted with a die with round bores therethrough to produce elongate solid round PLA bars or alternatively, through a die having elongate slits therethrough to produce solid rectangular PLA strips.
  • elongate solid round PLA bars may be corrugated around their linear axis.
  • elongate solid rectangular PLA bars may be corrugated around their linear axis.
  • the deformable nose bar may be a deformable aluminum strip.
  • the disposable, compostable surgical/medical mask 10 shown in FIGs. 1 to 6 may be referred to as a 3-ply disposable, compostable surgical/medical mask.
  • the 3-ply surgical/medical mask 10 may be produced with conventional disposable mask production equipment known to those skilled in this art, by concurrently unspooling a first spunbond PLA textile 20 with a meltblown PLA textile 30 and a second spunbond PLA textile 40 onto a conveyer belt to thereby form a 3-ply layered assembly that then passes through a set of pleating rollers to thereby form a flat pleated 3-ply assembly.
  • An extruded deformable PLA nosebar 35 material from a continuous roll is then inserted between the first spunbond PLA textile 20 with the meltblown PLA textile 30 near what will be upward-facing upper edge of the mask as the pleated 3-ply assembly is conveyed along by the conveyer belt.
  • the bottom and top longitudinal edges of the first spunbond PLA textile 20 are folded over the layered meltblown PLA textile 30 and the second spunbond PLA textile 40 and are concurrently heat embossed to form a first continuous multiple-welded strip 21 along the top longitudinal edge of the mask and a second continuous multiple- welded strip 22 along the bottom longitudinal edge of the mask (FIGs. 2A, 2B, 3A, 3B, 5).
  • Suitable heat-embossing processes include ultrasonically welding, hot roll calendaring, adhesive bonding, and the like.
  • the middle layer sandwiched between the two outer layers may be produced integrally or alternatively, bonded together for assembly into a 3-ply disposable, compostable surgical/medical mask.
  • the nosebar 35 is secured in place between top row and the second row of the multiple-welded strip 21 . It is optional if so desired, to insert the extruded deformable nosebar material between the melt-blown PLA textile 30 and the outward-facing second spunbond PLA textile 40 prior to the heat embossing step, for example, by ultrasonic welding. It is optional if so desired, to have the extruded deformable nosebar material positioned between the top two welded strips of the plurality welded strips at the top edge of the mask.
  • the 3-ply disposable, compostable soft ear loop strips 50 may be produced by concurrently unspooling a first spunbond PLA textile with a compostable elastic polymeric resin film and a second spunbond PLA textile to thereby form a 3-ply layered assembly comprising the compostable elastic film sandwiched between the first and second spunbond PLA textile layers.
  • the 3-ply layered assembly may then be bonded together by a heat embossing process to produce a continuous intermediate 3-ply laminate textile.
  • the continuous intermediate textile may then be activated by conveyance through one or more stages of rollers having circumferential grooves of generally rectangular or triangular form that closely mesh together to thereby stretch the two outer inelastic layers and cause a permanent elongation in the 3-ply laminate textile in the cross direction (CD) that does not exceed the elastic limit of the elastic film layer sandwiched between the two outer spunbond PLA textile layers.
  • the elongation of two outer spunbond PLA textile layers caused by conveyance through the rollers activates the 3-ply laminated textile and to thereby provide a soft resilience that enables the textile to be stretched and then return to its original shape in the cross direction (CD) while maintaining stiffness in the machine direction (MD).
  • the activated 3-ply stretchable textile may then be cut into elongate strips along the cross-direction axis of the activated 3-ply stretchable textile to thereby form 3-ply stretchable soft ear loop strips 50.
  • the disposable, compostable surgical/medical masks 10 may be assembled by ultrasonically welding of the ends of a first 3-ply stretchable soft ear loop strip 50 about the top corner 24a and bottom corner 25a of one side edge 23a of the laminated 3-ply face-mask component, and then ultrasonically welding of the ends of a second. 3-ply stretchable soft ear loop strip 50 about the top corner 24b and bottom corner 25b of the opposite side edge 23b of the laminated 3-ply face-mask component to thereby produce a disposable, compostable surgical/medical mask 10 according to this disclosure.
  • the continuous mask assemblies may be separated by cutting bars into individual disposable, compostable pleated surgical/medical masks 10.
  • the disposable, compostable, surgical/medical masks 10 may be assembled by ultrasonically welding of the ends of a first 3-ply stretchable soft ear loop strip 50 about the top corners 24a, 24b, and then ultrasonically welding of the ends of a second 3-ply stretchable soft ear loop strip 50 about the bottom corners 25a and bottom corner 25b of the opposite side edge 23b of the laminated 3-ply face-mask component to thereby produce another embodiment of a disposable, compostable surgical/medical mask according to this disclosure.
  • a suitable compostable elastic film for use in preparing the soft-resilient ear loops disclosed herein may be prepared from one of TERRATEK® FLEX FX2200, TERRATEK® FLEX FX1515, TERRATEK® FLEX GDH-B1 FA, all available from Green Dot Bioplastics Inc. Emporia, KS, USA (TERRATEK is a trademark owned by Green Dot Bioplastics LLC, Cottonwood Falls, KS, USA), and the like.
  • the first and second PLA textiles used to produce a 3-ply stretchable textile suitable to produce stretchable soft ear loop strips may be meltblown PLA textiles.
  • the 3-ply layered laminate assembly may be bonded together by passage through a hot-roll calendaring apparatus.
  • 3-ply layered laminate assembly may be bonded together by adhesive bonding.
  • the 3-ply layered laminate assembly may be provided with a pair of resilient elastic ear loops 45 (FIG. 6A) in place of the 3-ply soft ear loops 50 (FIG. 6B).
  • FIGs. 7 to 10 An embodiment of an example of a disposable, compostable 4-ply surgical/medical mask 60 disclosed herein is shown in FIGs. 7 to 10.
  • the disposable, compostable surgical/medical mask 60 has an inward-facing outer layer 85 made from a spunbond PLA textile, an outward-facing outer layer 65 made from a spunbond PLA textile, two middle layers 75, 80 made from meltblown PLA textile sandwiched between the outward-facing and inward-facing layers 65,85, and a deformable nosebar 70 formed from extruded PLA.
  • the compostable, disposable surgical/medical mask 60 may be referred to as a 4-ply compostable, disposable surgical/medical mask.
  • the 4-ply compostable, disposable surgical/medical mask 60 may be produced with conventional disposable mask production equipment known to those skilled in this art, by concurrently unspooling a first spunbond PLA textile 65 with two meltblown PLA textiles 75, 80 and a second spunbond PLA textile 850 onto a conveyer belt to thereby form a 4-ply layered assembly (FIG. 7A) that then passes through a set of pleating rollers to thereby form a flat pleated 4-ply assembly (FIG. 7B).
  • An extruded deformable PLA nosebar 70 material from a continuous roll is then inserted between the first spunbond PLA textile 75 and the first meltblown PLA textile 75 near what will be upward-facing upper edge of the mask as the pleated 4-ply assembly is conveyed along by the conveyer belt.
  • the bottom and top longitudinal edges of the first spunbond PLA textile 95 are folded over the layered meltblown PLA textiles 75, 80 and the second spunbond PLA textile 85 and are concurrently heat embossed to form a first continuous multiple-welded strip along the top longitudinal edge of the mask and a second continuous multiple-welded strip along the bottom longitudinal edge of the mask.
  • Suitable heat-embossing processes include ultrasonically welding, hot roll calendaring, adhesive bonding, and the like.
  • the nosebar 35 is secured in place between top edges of the outward-facing spunbond textile and the first meltblown textile layer 75. It is optional if so desired, to insert the extruded deformable nosebar material between the top edges of the two melt-blown PLA textiles 75, 80 prior to the heat embossing step, for example, by ultrasonic welding. It is optional if so desired, to have the extruded deformable nosebar material positioned between top edges of the second meltblown textile layer 80 and the inward-facing spunbond textile 85. It is optional to substitute deformable aluminum nosebars in place of the extruded deformable nosebar materials.
  • outward-facing and inward-facing spunbound textile layers 65, 85 may be considered to be and may be referred to as barrier layers. It is also to be noted that the two middle meltblown PLA textile layers 75, 80 may be considered to be and may be referred to as filtration layers.
  • the next step after the upper and lower edges of the flat pleated 4-ply assembly comprising the inward-facing spunbond PLA textile layer 85, the middle meltblown PLA textile layers 75, 80, the outward-facing meltblown PLA textile layer 65 are laminated with a deformable nosebar 70 placed near the top edges of two selected textile layers, is ultrasonically welding to form the welded top and bottom strips, followed by ultrasonically welding the side edges together, followed ultrasonically welding each of the pair of ear loops 90, 95 FIGs. 8A, 8B) to the upper corners and bottom corners of the 4-ply disposable, compostable surgical/medical mask 60.
  • Another example embodiment relates to lamination of layered textile assemblies to provide 3-ply or 4-ply disposable, compostable face masks according to the present disclosure, that selectively may pass (i) level 1 of the ASTM F2100 Standard Specification for Performance of Materials used in Medical Face Masks for use in environments wherein there is low risk of fluid exposure (no splashes or sprays expected), or alternatively, (ii) level 2 of the ASTM F2100 Standard Specification for use in environments wherein there is moderate risk of fluid exposure (some occurrence of splashes or sprays expected), or alternatively (iii) level 3 of the ASTM F2100 Standard Specification for use in environments wherein there is a high risk of fluid exposure (likely occurrence of splashes or sprays expected).
  • suitable layers of spunbond PLA textiles that may pass a selected level of ASTM F2100 Standard Specification include single layers having a GSM value (weight in grams per square metre) from a range of 20 to 65, for example 25 GSM, 40 GSM, 50 GSM. Also suitable are double layers of spunbond PLA textiles having a 20/20 GSM or a 25/25 GSM or a 30/30 GSM.
  • doubled-layered meltblown PLA textiles and doublelayered spunbond PLA textiles may pass a selected ASTM F2100 level may be thinner than single-layer meltblown and spunbond PLA textiles GSMs required to pass the same ASTM F2100 level.
  • a double-layered spunbond PLA textile with a GSM of 25/25 may be thinner than a single-layer spunbond PLA textile having a GSM of 40 or 50.
  • Suitable 3-ply disposable, compostable masks configured to pass level 1 or alternative, level 2 or alternatively, level 3 of the ASTM F2100 Standard Specification, may comprise an outward-facing spunbond layer, a meltblown middle layer, and an inward-facing spunbond layer. It was found that this configuration was able to achieve the performance requirements for level 3 ASTM F2100 Standard Specification.
  • the overall construction of the masks can be reduced in weight and therefore, in cost. Additionally, with two layers of meltblown, the barrier properties of one layer can be varied in relation to the other. This allows for a more optimal construction of the mask which results in exceeding the minimum performance requirements of the mask.
  • Suitable 4-ply disposable, compostable masks configured to pass level 1 or alternative, level 2 or alternatively, level 3 of the ASTM F2100 Standard Specification, may comprise an outward-facing spunbond layer, two meltblown middle layers, and an inwardfacing spunbond layer or alternatively, an outward-facing spunbond layer, a middle spunbond layer, a meltblown middle layer, and an inward-facing spunbond layer.
  • FIG. 10A is a micrograph of a double-layer meltblown PLA textile taken at a 1000X magnification, wherein it is apparent that the diameters of the meltblown fibers were in a range of 1 pm to 10 pm.
  • FIG. 10B is a micrograph of a double-layer spinbond PLA textile taken at a 250X magnification, wherein it is apparent that the diameters of the spunbond fibers were in a range of 10 pm to 20 pm.
  • the performance of the single-layer and double-layer meltblown PLA textiles may be improved by corona charging of the meltblown PLA textiles with forward/re verse charging with negative ions.
  • the corona charging process creates an electrostatic charge on the fibers of the meltblown textile and is used to increase the filtration efficiency of the media while allowing the pressure drop through the media to remain within the ASTM F2100 Standard Specification performance requirements of the mask specification.
  • Corona charging typically takes place in the production environment using ambient air around the manufacturing site.
  • Charging for typical filtration media utilizes negative corona charging ions (typically 30kV - 100kV DC potential) and is applied to both surfaces of the filter media during production.
  • An example of a suitable final charging process for a meltblown textile may be -30kV top side, -30kV bottom side, +60kV top side. However, those skilled in these arts will know how to vary the process to obtain their desired results.
  • hydrophobicity of the spunbond and meltblown PLA textiles may be increased by incorporation of selected additives during production of the textiles to modify the surface charge of the fibers and/or to modify the surface structure of the fibers.
  • Some additives such as metallic soaps may bloom to the surface of the fibers during processing and thereby create a waxy coating that will increase the hydrophobicity of the textile.
  • Other additives may include depositing nanospheres onto the fiber surfaces to thereby modify their surface structures and to increase their hydrophobic properties.
  • the pore size distributions in a single-layer meltblown PLA textile (FIG. 11) and in a double-layer meltblown PLA textile (FIG.12) were determined with a capillary flow porometer iPore-1050A (Porous Materials Inc.).
  • the thickness of the single-layer meltblown PLA textile (FIG. 11 ) was in the range of about 229 pm to 305 pm with a GSM of about 40.
  • the thickness of the double-layer meltblown PLA textile (FIG. 12) was in the range of about 152 pm to 229 pm with a GSM of about 25/25. Comparisons of the data in FIGs.
  • FIG. 11 and 12 shows that the pore sizes in the double-layer material meltblown PLA textile (FIG.12) are generally smaller and tighter than in the single-layer meltblown PLA textile (FIG. 11 ). Accordingly, double-layer material meltblown PLA textile (FIG.12) may reduce porousity and provide a better barrier to aerosols in comparison to the single-layer meltblown PLA textile (FIG. 11 ). It was also noted that the thinner double-layer material meltblown PLA textile had a much “softer” tactile feel and would be less expensive to produce than the single-layer meltblown PLA textile.
  • FIG. 13 shows the particulate filtration efficiencies (PFE) of a 4-ply disposable, compostable mask comprising an outward-facing spunbond layer, a middle spunbond layer, a meltblown middle layer, and an inward-facing spunbond layer (solid line with dark-shaded 95% confidence interval) with a 4-ply disposable, compostable mask comprising an outward-facing spunbond layer, two meltblown middle layers, and an inward-facing spunbond layer (dashed line with light-shaded 95% confidence interval).
  • PFE particulate filtration efficiencies
  • Multivariable correlation analyses were done with 192 4-ply masks configured with an outward-facing spunbond layer, a middle spunbond layer, a meltblown middle layer, and an inward-facing spunbond layer (FIG. 14) and with 480 4-ply masks configured with an outward-facing spunbond layer, two meltblown middle layers, and an inward-facing spunbond layer (FIG. 15).
  • the multivariable analysis indicated the strongest contributor to blood penetration resistance was Particulate Filtration Efficiency (PFE) which prompted further investigations into the causality of PFE to blood penetration resistance. From a theoretical sense it can be shown that fiber diameter, packing density and thickness can be used to predict PFE (Russel, S.J., 2007, Handb9ook of Nonwovens.
  • FIG. 16A No charge: control
  • FIG. 16B Double N: negative corona charge on both sides of the textile
  • FIG. 16C Double N + P: negative corona charge on both sides of the textile plus positive charge on one side.
  • FIG. 16D P only: positive corona charge only
  • FIGs. 16A-16D in FIG. 16 indicated that the best-performing textile was the double N negative corona charge on both sides of the textile plus P positive charge on one side (FIG. 16C). Although the positive corona charge provided an apparent better contact angle (FIG. 16F), the textile receiving this corona charge process did not provide the required PFE performance.
  • the dimensions of the disposable, compostable, pleated surgical/medical masks at this according to this disclosure may have a length selected from a range of about 12 cm to about 21 cm and therebetween, and a width selected from a range of about 6 cm to about 13 cm.
  • the disposable, compostable, pleated surgical/medical masks disclosed herein suitable for use by toddlers and young children from the ages of 2 yrs old to 6 yrs old may have a length selected from a range of about 12 cm to about 14 cm and a width selected from a range of about 6 cm to about 8 cm.
  • the disposable, compostable, pleated surgical/medical masks disclosed herein suitable for use by children and young juveniles from the ages of about 6 yrs old to about 14 yrs old may have a length selected from a range of about 13 cm to about 16 cm and a width selected from a range of about 7 cm to about 9 cm.
  • the disposable, compostable, pleated surgical/medical masks disclosed herein suitable for use by young adults and adults may have a length selected from a range of about 15 cm to about 21 cm and a width selected from a range of about 9 cm to about 13 cm.
  • Particularly suitable dimensions for disposable, compostable, pleated surgical/medical masks disclosed herein for adults may have a length of about 17.5 cm and a width of about 10 cm.
  • a disposable, compostable, pleated surgical/medical mask configured as disclosed herein may be easily mounted by a user onto their face and secured in place, by simply unfolding the pleats to form a 3-dimensional structure as shown in FIG 4A, and then separating and activating the soft-resilient ear loop strips 50a from the side edges 23a, 23b as shown in FIG. 4B.
  • the soft-resilient ear loop strips 50a can then be looped around the user’s ears.
  • An advantage of the present disposable, compostable, pleated surgical/medical mask with soft-resilient ear loops is that the mask may be worn by a user for an extended period of time without experiencing discomforts associated with prior art disposable surgical/medical masks with elastic ear loops such as pinching and loss of sensory sensation around the ears.
  • disposable, compostable, pleated surgical/medical masks disclosed herein comprising PLA textiles, deformable nosebars, and soft-resilient PLA ear loops is that they can be simply and easily disposed by composting.
  • used disposed compostable masks configured as disclosed herein may be collected in bulk and then conveyed to a composting site.

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  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Materials For Medical Uses (AREA)
  • Respiratory Apparatuses And Protective Means (AREA)

Abstract

Sont divulgués des masques chirurgicaux/médicaux jetables et compostables comprenant (i) un élément de masque facial à trois plis, les deux couches externes étant un textile de PLA filé-lié et la troisième couche centrale étant un textile de PLA obtenu par fusion-soufflage, (ii) une barre de nez déformable formée à partir d'un extrudat de PLA, et (iii) une paire de bandes de boucles latérales souples, étirables, allongées, de largeur étroite à trois plis, les deux bandes externes étant un textile de PLA filé-lié et la troisième couche intermédiaire étant un film élastique compostable. Certains modes de réalisation concernent des masques chirurgicaux/médicaux jetables et compostables à quatre plis, comprenant deux couches externes comprenant chacune un textile de PLA filé-lié et deux couches intermédiaires comprenant un textile de PLA obtenu par fusion-soufflage. Certains modes de réalisation concernent des masques chirurgicaux/médicaux jetables et compostables à quatre plis comprenant deux couches externes comprenant chacune un textile de PLA filé-lié, une couche intermédiaire comprenant un textile de PLA filé-lié et une couche intermédiaire comprenant un textile de PLA obtenu par fusion-soufflage.
PCT/CA2022/051483 2021-10-06 2022-10-06 Masques chirurgicaux/médicaux jetables et compostables et leurs procédés de production WO2023056562A1 (fr)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2824773A1 (fr) * 2011-01-17 2012-07-26 Royal Natural Medicine, S.R.O. Masque facial et son procede de fabrication
CN103445328A (zh) * 2013-07-29 2013-12-18 天津开发区金衫包装制品有限公司 基于纯棉纱布的抗菌防尘口罩及其加工方法
US20150059772A1 (en) * 2013-08-29 2015-03-05 3M Innovative Properties Company Filtering face-piece respirator having darted mask body
US20160174631A1 (en) * 2014-12-23 2016-06-23 Profit Royal Pharmaceutical Limited Protective masks with coating comprising different electrospun fibers interweaved with each other, formulations forming the same, and method of producing thereof
CN113068882A (zh) * 2021-03-30 2021-07-06 江苏美韦纶新材料科技有限公司 一种全降解口罩及制作方法
EP3915647A1 (fr) * 2020-05-28 2021-12-01 Eurofilters Holding N.V. Masque de protection respiratoire
CN215224929U (zh) * 2021-02-08 2021-12-21 龙岩市星泰量科技有限公司 一种pla全降解口罩

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2824773A1 (fr) * 2011-01-17 2012-07-26 Royal Natural Medicine, S.R.O. Masque facial et son procede de fabrication
CN103445328A (zh) * 2013-07-29 2013-12-18 天津开发区金衫包装制品有限公司 基于纯棉纱布的抗菌防尘口罩及其加工方法
US20150059772A1 (en) * 2013-08-29 2015-03-05 3M Innovative Properties Company Filtering face-piece respirator having darted mask body
US20160174631A1 (en) * 2014-12-23 2016-06-23 Profit Royal Pharmaceutical Limited Protective masks with coating comprising different electrospun fibers interweaved with each other, formulations forming the same, and method of producing thereof
EP3915647A1 (fr) * 2020-05-28 2021-12-01 Eurofilters Holding N.V. Masque de protection respiratoire
CN215224929U (zh) * 2021-02-08 2021-12-21 龙岩市星泰量科技有限公司 一种pla全降解口罩
CN113068882A (zh) * 2021-03-30 2021-07-06 江苏美韦纶新材料科技有限公司 一种全降解口罩及制作方法

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CAMPAIGN CAMPAIGN: "3 Ply Soft Elastic BIG EAR LOOP Surgical Face Mask", YOUTUBE, XP093060759, Retrieved from the Internet <URL:https://www.youtube.com/watch?v=MwDTngRNRqc> [retrieved on 20230704] *

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