WO2023275547A1 - Filtre biodégradable - Google Patents

Filtre biodégradable Download PDF

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Publication number
WO2023275547A1
WO2023275547A1 PCT/GB2022/051674 GB2022051674W WO2023275547A1 WO 2023275547 A1 WO2023275547 A1 WO 2023275547A1 GB 2022051674 W GB2022051674 W GB 2022051674W WO 2023275547 A1 WO2023275547 A1 WO 2023275547A1
Authority
WO
WIPO (PCT)
Prior art keywords
biodegradable
outer layers
thermoplastic
fibres
filtration membrane
Prior art date
Application number
PCT/GB2022/051674
Other languages
English (en)
Inventor
Volodymyr NESIN
Johann BOEDECKER
Original Assignee
Pentatonic Limited
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.)
Filing date
Publication date
Application filed by Pentatonic Limited filed Critical Pentatonic Limited
Publication of WO2023275547A1 publication Critical patent/WO2023275547A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • 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
    • A—HUMAN NECESSITIES
    • A62—LIFE-SAVING; FIRE-FIGHTING
    • A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
    • A62B23/00—Filters for breathing-protection purposes
    • A62B23/02—Filters for breathing-protection purposes for respirators
    • A62B23/025—Filters for breathing-protection purposes for respirators the filter having substantially the shape of a mask
    • A—HUMAN NECESSITIES
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    • A62B7/10—Respiratory apparatus with filter elements
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/14—Fibrous additives or fillers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1607—Degradability
    • D06N2209/1614—Biodegradable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/10—Clothing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/30—Filters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by spraying components on the web

Definitions

  • the present invention relates to a biodegradable filter for a mask, a method of manufacturing the filter, and a mask comprising the filter.
  • Single-use surgical masks which are arguably the most prevalent in society today, are primarily composed of synthetic, woven polymeric materials. This type of mask cannot be recycled, and may even break down into micro or nanoplastics, which are particularly concerning pollutants. As such, single-use disposable masks are now largely contributing to the already substantial plastic waste problem. For instance, according to a survey by TradeWaste.co.uk in November 2020, an average of 53 million disposable masks were sent to landfill every day in the UK. Additionally, not only are single-use surgical masks contributing to the global plastic problem, they also pollute water and can substantially harm wildlife.
  • the disclosed invention is intended to overcome or ameliorate at least some aspects of this problem.
  • a biodegradable filter for a mask comprising: at least two outer layers comprising cellulosic-based fibres, bast fibres, protein-based fibres, and/or polyvinyl alcohol fibres; and a filtration membrane located between the two outer layers, wherein the filtration membrane is a non-woven nanofibre layer having an areal density in the range of from about 0.2 and about 10 g/m 2 ; and wherein the at least two outer layers comprise a thermoplastic additive and/or wherein the filter comprises a thermoplastic layer located between the filtration membrane and each of the at least two outer layers.
  • the biodegradable filter according to the first aspect of the invention is biodegradable and home or industrially compostable. As such, the filter according to the invention is considerably more environmentally friendly compared to existing filters.
  • cellulosic-based fibres relates to fibres made of ethers or esters of cellulose.
  • Examples of cellulosic-based fibres include but are not limited to viscose, lyocell, bamboo, cotton, and sisal.
  • the cellulosic fibres may be composites with synthetic or other natural polymers.
  • the fibres may also contain hemicellulose.
  • the term “bast fibres” refers to plant fibres from the phloem or bast surrounding the stem of certain dicotyledonous plants. Examples of bast fibres include but are not limited to flax, hemp, jute, ramie, kenaf, or abaca.
  • protein-based fibres relates to fibres derived from animals or insects.
  • protein-based fibres include but are not limited to silk, wool or fur.
  • Natural fibres, such as those described above, are beneficial as they deliver natural hydrophilicity to the filter, which allows for efficient absorption of breathing moisture.
  • the filtration membrane comprises a non-woven nanofibre layer having an areal density in the range of from about 0.2 to about 10 g/m 2 , optionally in the range of from about 0.2 to about 6 g/m 2 . Areal densities within this range result in a membrane that has higher filtration capacity, as the fine nature of the fibres are able to effectively trap small particles, often down to the nano or sub-nano size range.
  • the outer layers serve as protective layers to the filtration membrane and also provide structural integrity to the biodegradable filter.
  • the filter comprises at least two outer layers, but may further comprise additional outer layers depending on the structural properties desired.
  • the areal density of each of the at least two outer layers may be in the range of from about 10 to about 100 g/m 2 , optionally in the range of from about 15 to about 35 g/m 2 . This density range in particular provides the optimum balance between structural rigidity, and flexibility and breathability of the filter.
  • thermoplastic additive relates to a plastic or polymer material that is malleable at an elevated temperature and is then able to solidify upon cooling. Addition of a thermoplastic additive enhances the structural integrity of the product. Moreover, inclusion of a thermoplastic additive within the outer layers allows for connection of the elements of the filter by ultrasonic bonding. As used herein, the term “ultrasonic bonding” relates to standard sonic welding processes which use sound waves and pressure in order to fuse components together.
  • the thermoplastic additive comprises thermoplastic fibres.
  • the thermoplastic additive may comprise thermoplastic fibres present in the range of from about 15 wt. % to about 80 wt. % of the total weight of fibres present in each of the at least two outer layers, optionally in the range of from about 25 wt. % to about 50 wt. % of the total weight of fibres present in each of the at least two outer layers.
  • Use of thermoplastic fibres blended with the fibres present in the at least two outer layers provides for a simplified manufacturing process.
  • Thermoplastic fibres include but are not limited to biodegradable polyamides, a copolymer of polylactic acid /poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PLA/PHBV), biodegradable polypropylene (PP), biodegradable polyethylene terephthalate (PET) or polytrimethylene terephthalate (PTT).
  • biodegradable polypropylene (PP)” and “biodegradable polyethylene terephthalate (PET)” relate to PP and PET comprising a biodegradable plastic additive respectively.
  • a “biodegradable plastic additive” is an additive that is used to increase the biodegradation of the polymer material in question, so that it can be broken down by microorganisms.
  • An example of a biodegradable plastic additive includes but is not limited to BioSphere 201®.
  • the biodegradable plastic additive is typically present in the range of about 1 wt. % to about 4 wt. % to provide optimum biodegradability of polypropylene whilst maintaining a relatively narrow nanofibre diameter distribution and maintaining the physical properties of the polymer.
  • the term “thermoplastic layer” is a quantity or thickness of plastic or polymer material that is malleable at an elevated temperature and is then able to solidify upon cooling.
  • thermoplastic layer includes but is not limited to a biodegradable polyamide (such as biodegradable Nylon), poly 3-hydroxybutyrateco-3-hydroxyvalerate (PHBV), polylactic acid (PLA), biodegradable polyester base polymers, polyurethanes, polyfurfuryl alcohol or thermoplastic starch.
  • a biodegradable polyamide such as biodegradable Nylon
  • PHBV poly 3-hydroxybutyrateco-3-hydroxyvalerate
  • PLA polylactic acid
  • biodegradable polyester base polymers polyurethanes
  • polyfurfuryl alcohol or thermoplastic starch thermoplastic starch
  • the thermoplastic layer is provided as a coating on a surface of a respective one of each of the at least two outer layers.
  • surface relates to an inner surface of the outer layer away from the external environment.
  • the thermoplastic layer is a coating, it is in the range of 0.5% to 1% of the total areal density of each of the at least two outer layers.
  • a coating allows for uniform and controlled coverage of the thermoplastic material, which provides for strong adhesion of the outer layers and filtration membrane following ultrasonic bonding.
  • the thermoplastic layer can be mixed with additives, such as plasticisers, which facilitate application as a coating.
  • the filtration membrane is provided as a coating on a surface of at least one of the at least two outer layers.
  • Application of the filtration membrane as a coating minimises the individual components present in the filter, and thereby results in a simpler manufacturing process.
  • a coating means that the filtration membrane is securely integrated into at least one of the at least two outer layers.
  • the at least two thermoplastic layers are provided as a coating on a surface of the at least two outer layers, and wherein the filtration membrane is provided as a coating on a surface of at least one of the at least two outer layers, typically the filtration membrane will be provided as a coating on the thermoplastic layer.
  • the thermoplastic layer it may also be possible to provide the thermoplastic layer as a coating on the filtration membrane.
  • the filtration membrane comprises nanofibres having a diameter in the range of from about 50 to about 500 nm, optionally having a diameter in the range of from about 100 nm to about 400 nm. Nanofibres in this particular range provide a filtration membrane with enhanced porosity, which enhances the breathability of the filter whilst also being electrostatically charged to enhance the performance of the filter.
  • porosity relates to the voids present in between the fibres formed, which are able to hold fluid/particles.
  • the filtration membrane comprises a biodegradable polymer.
  • the biodegradable polymer may be selected from polycaprolactone (PCL), polyhydro xybutyrate (PHB), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polyhydroxyalkanoate (PHA), polytetramethylene adipate- coterephthalate (PTAT), poly 3-hydroxybutyrateco-3-hydroxyvalerate (PHBV), polybutylene succinate (PBS), polytrimethylene terephthalate (PTT), polyvinyl alcohol (PVA), polyglycolic acid (PGA), or combinations thereof.
  • PCL polycaprolactone
  • PHB polyhydro xybutyrate
  • PLA polylactic acid
  • PBAT polybutylene adipate terephthalate
  • PHA polyhydroxyalkanoate
  • PTA polytetramethylene adipate- coterephthalate
  • PHBV poly 3-hydroxybutyrateco-3
  • Biodegradable polymer blends may include but are not limited to PHB/PCL, PCL/PLA, PLA/PHA, PLA/PHB, PLA/ PGA, PLA/PHBV, PLA/PBAT, PHBV/ PBAT, and PHBV/PBS.
  • the ratio of the polymers may be present in the ratio of 5:95, 10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20, 90: 10, or 95:5.
  • the polymers are biodegradable, resulting in a more environmentally friendly filter.
  • PHB, PHA, PCL, PBAT and PLA/PCL in particular are home compostable.
  • PLA is industrially compostable.
  • the biodegradable polymer may further comprise thermoplastic starch.
  • Thermoplastic starch may be incorporated such that a composite is formed, for instance, using conventional synthetic thermoplastic processing techniques (for instance re-compounding, polymer coating, extrusion and injection). Incorporation of thermoplastic starch into the biodegradable polymer enhances the structural and mechanical properties of the filtration membrane.
  • the filtration membrane is entirely formed of a biodegradable material, such as a biodegradable polymer and/or protein-based fibre.
  • a mask comprising: a mask body; and ear loops arranged proximate to opposing sides of the mask body; wherein the mask body comprises a biodegradable filter according to the first aspect of the invention.
  • the term “mask body” relates to the portion of the mask used to cover the nose and mouth region of the face of the user; and the term “ear loop” relates to the portion of the mask that is positioned around the ears to ensure the mask stays in place.
  • a mask comprising the biodegradable filter according to the first aspect of the invention is considerably more environmentally friendly compared to standard disposable plastic masks currently in circulation. As such, their disposal would have less of a deleterious impact on climate change.
  • the biodegradable filter is replaceable within the mask body. Provision of a replaceable filter allows for easy replacement of the filter once the current filter being used has reached its maximum filtration capacity.
  • the ear loops are connected to the mask body via heat-bonding, stitching and/or via a biodegradable adhesive.
  • Heat-bonding, stitching, and/or biodegradable adhesives allow for strong attachment of the ear loops to the mask body, which reduces the possibility of detachment and therefore results in a more robust and secure mask.
  • each ear loop comprises an elastomeric material, e.g. a biodegradable natural rubber, or a biodegradable fabric, e.g. natural or synthetic fibres, such as biodegradable polyamide fibres (e.g. Nylon).
  • a biodegradable natural rubber or a biodegradable fabric enhances the biodegradability and compostability of the mask.
  • the mask body further comprises a biodegradable nose clip.
  • the term "nose clip” relates to the part of the mask positioned against the user's nose to help keep the mask in place.
  • a nose clip is beneficial as it helps direct air out the sides of the mask, which is particularly beneficial if the user wears glasses, as this helps prevent build-up of condensation.
  • a nose clip also aids with the comfort of the mask.
  • the biodegradable nose clip comprises a biodegradable metallic layer located between at least two layers of paper.
  • the biodegradable metallic layer of the nose clip comprises magnesium, iron, zinc, or biodegradable alloys thereof. These metals are readily available, cheap, and their use further enhances the biodegradability and compostability of the mask.
  • a method of manufacturing a filter comprising the following steps: i) producing the filtration membrane by centrifugal spinning or electrospinning technology; ii) providing at least two outer layers, and iii) connecting the filtration membrane and the at least two outer layers by ultrasonic bonding; wherein the method comprises providing the at least two outer layers comprising a thermoplastic additive and/or wherein the method further comprises providing a thermoplastic layer between the filtration membrane and each of the at least two outer layers.
  • the term “electrospinning” refers to the process of generating spun nanofibres using high voltage to create an electric field between a droplet of solution at the tip of a needle and a collector plate.
  • centrifugal spinning refers to an alternative process of generating nanofibres using a centrifugal force as opposed to high voltage. Spinning fluid is placed on a rotating head having a nozzle, and when the centrifugal force overcomes the surface tension of the fluid, a liquid jet is ejected from the tip of the nozzle. The jet can then be collected and processed to produce fibres.
  • the filtration membrane is produced by electrospinning technology.
  • the filtration membrane is coated on a surface of at least one of the at least two outer layers.
  • the filtration membrane is directly spun onto a surface of at least one of the outer layers, which effectively acts as a substrate. Applying the filtration membrane as a coating streamlines the manufacturing process of the filter.
  • connecting the filtration membrane and the at least two outer layers may take place via melting the at least two thermoplastic layers followed by subsequent cooling.
  • the at least two thermoplastic layers are heated to a temperature in the range of from about 60°C to about 270°C, more typically in the range of from about 100°C to about 250°C.
  • the at least two thermoplastic layers are cooled at room temperature to below the melting point of the thermoplastic layer.
  • each thermoplastic layer is spray coated onto the at least two outer layers.
  • the two thermoplastic layers are powder coated. Powder coating provides for more accurate application of the thermoplastic layers, allowing for more even coverage and enhanced adhesion of the outer layers to the filtration membrane.
  • step (ii) the at least two outer layers are produced through a spun- laid process and calendar roll bonded.
  • spun-laid is the process used to melt polymers that are extruded through many small holes and collected on a belt. The filaments adhere to each other before cooling down. Fabric will have greater strength, but lower flexibility.
  • a spun-laid web is also self-bonded during the web forming process and additionally stabilized by the calendar bonding step, optionally accompanied by hydro-entaglement that uses high-pressure water jet to entangle the fibers.
  • calendar roll bonding relates to processing of a spun laid web via calendar rollers to generate a layer of material.
  • Calendar roll bonding is a type of thermal bonding, and is particularly advantageous in preparation of nonwovens as it is environmentally friendly.
  • no harsh chemicals are required; it does not cause water pollution, which is the case with chemical bonding; and it imparts a soft feel on the nonwoven, which enhances comfort for the user.
  • the roll may be patterned, which can improve abrasion resistance of the material, as well as producing an aesthetically pleasing fabric.
  • the fibres of the at least two outer layers are produced by treatment of pellets.
  • pellets are compounded, blended and/or ground; and said processed pellets are extruded into spun-laid fabric, which is then followed by calendar roll bonding to form a web.
  • the at least two outer layers can be produced by compounding, blending and/or grinding pellets of the respective material; extruding said processed pellets into filaments; crimping and cutting fibres from said filaments; and using a spun-laid process followed by calendar roll bonding to form a web.
  • carding can be used instead of spun-laid processing.
  • the term "carding" is the process used to separate and disentangle fibres to form a continuous web.
  • Figure 1 A schematic diagram of the construction of a biodegradable filter according to a first aspect of the invention.
  • Figure 2 A schematic diagram of the nose clip construction of a mask according to a second aspect of the invention.
  • Figure 3 (a) A scanning electron microscope (SEM) image of an outer layer of the biodegradable filter wherein the outer layer comprises viscose fibres; (b) a SEM image of a thermoplastic layer comprising biodegradable nylon; (c) a SEM image of a filtration membrane comprising electrospun PHB nanofibres.
  • SEM scanning electron microscope
  • Figure 4 A SEM image of electrospun PHB fibres at (a) a magnification of 1,000 (b) a magnification of 5,000; and (c) a magnification of 10,000.
  • Figure 5 (a) A SEM image of an outer layer comprising viscose fibres at a magnification of (i) 400 and (ii) 1,000; and (b) a SEM image of an outer layer comprising viscose fibres coated with a biodegradable nylon coating at a magnification of (i) 400 and (ii) 1,000.
  • FIG. 1 is a schematic diagram of the construction of a biodegradable filter according to an embodiment of the first aspect of the invention.
  • Two outer layers comprising viscose fibres 5 are positioned either side of a filtration membrane 10 comprising PHB fibres.
  • Two thermoplastic layers 15 are located between the filtration membrane and each of the at least two outer layers 5.
  • Thermoplastic layers 15 comprise biodegradable nylon and have been applied as a coating onto a surface of the two outer layers 5.
  • the two outer layers 5, the filtration membrane 10, and the two thermoplastic layers 15 have been bonded together via ultrasonic bonding.
  • FIG. 2 is a schematic diagram of the construction of a nose clip according to an embodiment of the second aspect of the invention.
  • Two layers 35 of undyed paper are positioned either side of iron wire 30.
  • the two layers 35 of undyed paper and the iron wire 30 are connected by use of water as a binder. Upon drying, the two layers 35 of paper and the iron wire 30 form a self-bonded web.
  • Figure 3 (a) to (c) are scanning electron microscope (SEM) images of an outer layer of the biodegradable filter wherein the outer layer comprises viscose fibres; a thermoplastic layer comprising biodegradable nylon; and a filtration membrane comprising electrospun PHB nanofibres respectively.
  • SEM scanning electron microscope
  • Figure 4 shows a SEM image of electrospun PHB fibres at (a) a magnification of 1,000 (b) a magnification of 5,000; and (c) a magnification of 10,000.
  • the images were taken using a SEMOSCOPE (Turkey).
  • SEMOSCOPE Tetra-Semiconductor
  • Figure 5(a)(i) shows a SEM image of an outer layer comprising viscose fibres at a magnification of 400 and figure 5(a)(ii) is at a magnification of 1,000.
  • Figure 5(b)(i) shows a SEM image of an outer layer comprising viscose fibres coated with a biodegradable nylon coating at a magnification of 400 and figure 5(b)(ii) is at a magnification of 1,000.
  • the images were taken using a SEMOSCOPE (Turkey).
  • PHB fibres were electrospun using a multi-nozzle electrospinning system (Ne300 Laboratory Scale - INOVENSO, Turkey).
  • a solution comprising 3g PHB from biomer, 77.6g chloroform, 19.4g tetrahydrofuran, and 0.08g of lithium chloride (LiCI) salt was prepared.
  • PHB was dissolved in chloroform with a heat of 130°C and stirred for two hours. The solution was then stirred for an additional five hours without heat. THF was then added to slow down the evaporation in the process and stirred for an additional two hours. To increase the conductivity, lithium chloride was added, and the mixture was stirred until the lithium chloride salt dissolved completely.
  • Viscosity was measured at room temperature (25 °C) using a rotating viscometer (Lamy Rheology Instruments, France) and the rotation speeds were between 0.3 and 250 rpm.
  • the conductivity of the solution was measured using Ohaus St 3100 (Switzerland) and was 0.3933 +/- 0.0047 ps/cm.
  • the prepared solution was fed into a 10ml syringe and the syringe was attached to a syringe pump.
  • electrospun PHB fibres are obtained using solution flow rates of 1.5-7 ml/h controlled by a syringe pump with distance of needle-collector (working distance) of 150-305 mm, a needle with a diameter of 1.2 mm, and voltage of 15- 90 kV.
  • Examples 2 to 25 show the filtration efficiency of filtration membranes of varying areal densities coated onto an outer layer.
  • the outer layer comprises viscose 10 fibres
  • the filtration membrane comprises polyhydro xybutyrate (PHB) fibres.
  • the average filtration efficiency was calculated according to EN 149 standard (European standard).
  • Feeding rates per pump are the total volume supplied on a set of 2 rods, consisting from 27 nozzles each. A peristaltic pump was used.
  • Substrate speed relates to the speed of the substrate passing through the working area (electrospinning area).

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  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Emergency Management (AREA)
  • Business, Economics & Management (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Dispersion Chemistry (AREA)
  • Pulmonology (AREA)
  • Filtering Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

Filtre biodégradable pourvu d'au moins deux couches externes formées à partir de fibres à base de cellulose, de fibres libériennes, de fibres à base de protéines, et/ou de fibres d'alcool polyvinylique. Une membrane de filtration de nanofibres non tissées est située entre les deux couches externes, et présente une densité surfacique se situant dans la plage allant de 0,2 à 10 g/m2. Les couches externes peuvent comprendre un additif thermoplastique et/ou une couche thermoplastique peut être située entre la membrane de filtration et les couches externes.
PCT/GB2022/051674 2021-07-01 2022-06-29 Filtre biodégradable WO2023275547A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
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KR20100004482A (ko) * 2008-07-04 2010-01-13 코오롱패션머티리얼 (주) 마스크
US20110114554A1 (en) * 2008-07-18 2011-05-19 Clarcor Inc. Multi-component filter media with nanofiber attachment
CN103445328B (zh) * 2013-07-29 2016-03-30 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
US20160250575A1 (en) * 2013-10-07 2016-09-01 Finetex Ene, Inc. Filter Comprising Nanofiber Between Substrates And Method For Manufacturing The Same

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Publication number Priority date Publication date Assignee Title
EP1953286A1 (fr) * 2007-02-01 2008-08-06 Nisshinbo Industries, Inc. Tissu et masque
KR102149121B1 (ko) * 2020-02-13 2020-08-27 윤영복 하이브리드 보건 위생용 마스크, 그리고 이의 제조 방법

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Publication number Priority date Publication date Assignee Title
KR20100004482A (ko) * 2008-07-04 2010-01-13 코오롱패션머티리얼 (주) 마스크
US20110114554A1 (en) * 2008-07-18 2011-05-19 Clarcor Inc. Multi-component filter media with nanofiber attachment
CN103445328B (zh) * 2013-07-29 2016-03-30 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
US20160250575A1 (en) * 2013-10-07 2016-09-01 Finetex Ene, Inc. Filter Comprising Nanofiber Between Substrates And Method For Manufacturing The Same

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