Compostable medical face mask
A compostable medical mask is provided with a printable outer non-woven layer. The outer non-woven layer includes bonded first fibers with first fiber diameters in a range from approximately 1 micron to approximately 100 microns. At least one intermediate non-woven filtration layer is provided. The intermediate non-woven filtration layer has second fibers having a second fiber diameter in a range from approximately 50 nanometers to approximately 800 nanometers. An inner non-woven layer for contacting a mask-wearer, the inner non-woven layer including bonded third fibers having third fiber diameters in a range from approximately 1 micron to approximately 100 microns. The compostable medical mask has a bacterial filtration efficiency of at least 98%, a sub-micron particulate filtration efficiency of at least 98%, a viral filtration efficiency of at least 98%, a splash resistance repelling synthetic blood at 160 mm Hg, and differential pressure of less than 5.0 mm H 2 O/cm 2 .
1 . A compostable medical mask comprising:
a first compostable polymer outer non-woven fabric layer with a printable surface having a contact angle for print ink of less than approximately 90 degrees, the first compostable polymer outer non-woven fabric layer including bonded first compostable polymer fibers having first compostable polymer fiber diameters in a range from approximately 1 micron to approximately 100 microns,
at least one second compostable polymer intermediate non-woven filtration layer;
the at least one second compostable polymer intermediate non-woven filtration layer comprising second compostable polymer fibers having a second compostable polymer fiber diameter in a range from approximately 50 nanometers to approximately 800 nanometers;
a third compostable polymer inner non-woven fabric layer for contacting a mask wearer, the third compostable polymer inner non-woven fabric layer including bonded third compostable polymer fibers having third compostable polymer fiber diameters in a range from approximately 1 micron to approximately 100 microns;
a compostable nose piece with shape-memory capability such that, when the mask is worn by a user, a close fit against the user's nose is ensured;
a compostable mask retainer having sufficient elasticity such that, when the mask is worn by a user, the mask is secured on to the user's face, creating a flexible seal between the mask and the user's face;
wherein the first compostable polymer outer non-woven fabric layer and the at least one second compostable polymer intermediate non-woven filtration layer are both composite compostable electrospun nanofiber filtration layers formed on compostable spunbond fabric substrates;
wherein the compostable spunbond fabric substrates comprise a first compostable polymer and a spunbond additive;
wherein the electrospun nanofiber filtration layers comprise a second compostable polymer in a concentration of 3-46%, compostable hydrophobic additives in a concentration of 2-35%, and salt additives in a concentration of 0.1-0.5%;
wherein the compostable medical mask has a bacterial filtration efficiency of at least 98%, a sub-micron particulate filtration efficiency of at least 98%, a viral filtration efficiency of at least 98%, a splash resistance repelling synthetic blood at 160 mmHg, and differential pressure of less than 5.0 mmH 2 O/cm 2 .
2 . The compostable medical mask of claim 1 , wherein the compostable medical mask meets international biodegradation standards of ASTM D6400, EN13432 and ASTM D5511.
3 . The compostable medical mask of claim 1 , wherein a surface density of the first compostable polymer spunbond fabric substrates range between 10 and 250 gsm.
4 . The compostable medical mask of claim 1 , wherein the first compostable polymer is selected from seaweed polysaccharides, poly (amino acid), polylactic acid, polyhydroxyalkanoate, polybutylene succinate, poly (lactic-co-glycolic), polyethylene oxide, poly (butylene adipate-co-terephthalate), chitosan, or cellulose acetate, and the spunbond additive is selected from one or more of nucleating agents, plasticizers, stabilizers, waterproofing agents, and antioxidants.
5 . The compostable medical mask of claim 1 , wherein the second compostable polymer is selected from seaweed polysaccharides, poly (amino acid), polylactic acid, polyhydroxyalkanoate, polybutylene succinate, poly (lactic-co-glycolic), polyethylene oxide, poly (butylene adipate-co-terephthalate), chitosan, or cellulose acetate.
6 . The compostable medical mask of claim 1 , wherein the hydrophobic additives are one or more of candelilla wax, montan wax, beeswax, castor oil, palm oil, or hemp seed oil, and the salt additives are one or more of lithium sulphate, magnesium bromide, potassium iodide, tetrabutylammonium chloride, sodium chloride, calcium chloride, ammonium chloride, or potassium chloride.
7 . The compostable medical mask of claim 1 , wherein a molecular weight range of the second compostable polymer is 30,000 to 200,000 g/mol.
8 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layer is prepared by electrospinning a compostable polymer in a solvent at a voltage from 20-100 kV, a spinneret feeding rate range of 1-200 ml/hour, a tip-to-collector distance range of 50 mm-350 mm, and a substrate speed range of 10-200 mm/min.
9 . The compostable medical mask of claim 8 , wherein the electrospun nanofiber filtration layer prepared by electrospinning is electrospun at a temperature range of 10-50° C. and a relative humidity range of 30-80%.
10 . The compostable medical mask of claim 1 , wherein the mask retaining is a pair of compostable and flexible ear loops.
11 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise polybutylene succinate in a concentration of 7.5-17.8% as the second compostable polymer, a mixture of montan wax and castor oil in a concentration of 5-12% as the compostable hydrophobic additives, and a mixture of ammonium chloride and lithium sulphate in a concentration of 0.1-0.5% as the salt additives.
12 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise a mixutre of seaweed polysaccharides and polyethylene oxide in a concentration of 12-35% as the second compostable polymer, a mixture of steric acid and castor oil in a concentration of 6-15% as the compostable hydrophobic additives, and a mixture of potassium chloride and lithium sulphate in a concentration of 0.1-0.5% as the salt additives.
13 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise a mixture of poly (amino acid) and polyhydroxyalkanoate in a concentration of 8-10% as the second compostable polymer, a mixture of alginates and castor oil in a concentration of 25-35% as the compostable hydrophobic additives, and a mixture of magnesium bromide and calcium chloride in a concentration of 0.1-0.5% as the salt additives.
14 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise polylactic acid in a concentration of 12-36% as the second compostable polymer, a mixture of beeswax, palm oil and montan wax in a concentration of 5-17% as the compostable hydrophobic additives, and a mixture of magnesium bromide and sodium chloride in a concentration of 0.1-0.5% as the salt additives.
15 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise polyhydroxyalkanoate in a concentration of 25-40% as the second compostable polymer, a mixture of stearic acid and castor oil in a concentration of 3-8% as the compostable hydrophobic additives, and a mixture of potassium iodide and tetrabutylammonium chloride in a concentration of 0.1-0.5% as the salt additives.
16 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise a mixture of poly (lactic-co-glycolic), starch and polyethylene oxide in a concentration of 30-46% as the second compostable polymer, a mixture of stearic acid and castor oil in a concentration of 5-10% as the compostable hydrophobic additives, and a mixture of magnesium bromide and lithium sulphate in a concentration of 0.1-0.5% as the salt additives.
17 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise cellulose in a concentration of 5-15% as the second compostable polymer, a mixture of castor oil, montan wax and beeswax in a concentration of 5-10% as the compostable hydrophobic additives, and a mixture of tetrabutylammonium chloride and sodium chloride in a concentration of 0.1-0.5% as the salt additives.
18 . The compostable medical mask of claim 1 , wherein the electrospun nanofiber filtration layers comprise a mixture of chitosan and polylactic acid in a concentration of 3-10% as the second compostable polymer, a mixture of carnauba wax and castor oil in a concentration of 2-5% as the compostable hydrophobic additives, and a mixture of ammonium chloride and potassium iodide in a concentration of 0.1-0.5% as the salt additives.