Compostable, biodegradable, breathable personal protective equipment (PPE)

Abstract

The present invention provides a compostable personal protective equipment (PPE) comprising a compostable plant-based material. Preferably, the compostable plant-based material comprises a compostable starch-based polymer. The compostable plant-based material comprises a compostable base material and a compostable sealing material. In another aspect, the present invention also provides a method for manufacturing a compostable personal protective equipment (PPE) comprising a compostable plant-based material. The compostable plant-based material comprises a compostable base material and a compostable sealing material. The compostable PPE can be integrally formed from a single piece of compostable material. The compostable PPE is preferably formed by a roll cutting process.

Description

Technical Field

[0001] This invention relates to compostable, biodegradable, and breathable personal protective equipment (PPE), such as PPE commonly used in healthcare environments, such as hospitals or nursing / convalescent homes. Background Technology

[0002] Single-use disposable medical garments such as aprons (called "splash aprons"), smocks, shoe covers, and head covers / hair covers are commonly used in healthcare settings, particularly hospitals and nursing facilities. Known single-use disposable medical garments are made of plastic materials, typically low-density polyethylene (LDPE). This known plastic material was chosen because of its resistance to liquids, a necessary property of PPE.

[0003] The materials used must be lightweight and thin (typically 12 to 16 microns for aprons and up to 35 microns for shoe covers, also known as "boot covers"), making it easier for wearers to perform necessary activities while wearing PPE (such as disposable aprons, shoe covers, or head / hair covers). PPE is intended for single use only in healthcare settings to ensure that infection is not spread between patients; therefore, PPE must be disposed of after single use.

[0004] PPE made of plastic materials is needed in all healthcare environments, as well as other environments such as medical technology, cleanrooms in the electronics industry, and food processing plants. This single-use PPE generates a large amount of plastic waste, resulting in significant environmental and economic costs in its disposal. For example, 100 million plastic aprons would generate 1,000 tons of plastic waste.

[0005] Some known PPEs are formulated to include additives for faster degradation of petrochemical-based PPEs. This invention aims to completely avoid the use of existing petrochemical-based PPEs.

[0006] Therefore, the present invention aims to mitigate the shortcomings of the prior art. Summary of the Invention

[0007] For many years, the aforementioned disposable PPE aprons have been used in healthcare settings and other environments described above. As a significant technological improvement relative to the status quo, the inventors have surprisingly invented compostable disposable personal protective equipment (PPE) comprising an apron, shoe covers, and a head / hair cover. This compostable disposable PPE is biodegradable and also meets the requirements for Class 1 medical devices under the Medical Devices Regulation (MDR) (EU) 2017 / 745.

[0008] Therefore, the present invention provides compostable personal protective equipment (PPE) comprising compostable plant-based material, and the PPE according to the present invention also meets the requirements of a Class 1 medical device according to the Medical Devices Regulation (EU) 2017 / 745, and can therefore be referred to as "medical-grade personal protective equipment (PPE)".

[0009] Therefore, the present invention provides a compostable, biodegradable, and breathable personal protective equipment (PPE) product comprising a compostable plant-based material, wherein the compostable plant-based material comprises a compostable starch-based polymer, and wherein the compostable, biodegradable, and breathable PPE meets the requirements of a Class 1 medical device according to the Medical Device Regulation (MDR) (EU) 2017 / 745.

[0010] Furthermore, preferably, according to the definition of "compostable" as specified in EU standards EN 13432 and ASTM 6400, the PPE is compostable, meaning that the bio-based material (e.g., starch-based material) meets the following characteristic: in a carbon dioxide-rich environment, the material degrades by at least 90% within 6 months. Therefore, the compostable PPE of the present invention meets the requirements of EU standards EN 13432 and ASTM 6400.

[0011] Furthermore, the compostable PPE of the present invention does not contain any enzymes or any other additives, which is necessary for the degradation of petrochemical-based PPE at a faster degradation rate.

[0012] It is also worth noting that the compostable PPE of the present invention has the advantage of being "soil-safe." Recently, in the context of soil quality, the terms "soil health" or "soil safety" have been used because these terms emphasize the soil's ability to provide multiple functions, including nutrient cycling, carbon sequestration and climate regulation, water purification and storage, and providing habitat for biodiversity. Therefore, the terms "soil health" and "soil safety" are defined as the soil's ability to continue as a living ecosystem sustaining plants, animals, and humans. Thus, the compostable PPE of the present invention can be composted and returned to the soil because it is "soil-safe" and does not affect the soil's ability to continue as an important living ecosystem.

[0013] Compostable plant-based materials include compostable matrix materials and compostable additive materials containing compostable sealants.

[0014] The compostable PPE of the present invention preferably comprises 95 w / w% to 97 w / w% of a compostable matrix material and 3 w / w% to 5 w / w% of a compostable additive material containing a compostable sealant.

[0015] The invented compostable material has a water repellency of 948 g / m³ at 38°C. 2 / sky.

[0016] The compostable material of the present invention has a weighing thickness of 12 to 35 micrometers.

[0017] The compostable material of this invention has an impact strength sufficient to withstand a 30 g drop from 660 mm.

[0018] The compostable material of the present invention has a tear resistance of 70.06 mN.

[0019] The compostable PPE product of the present invention can be in the form of a single-use medical apron.

[0020] The compostable PPE product of the present invention may further be in the form of a single-use medical shoe cover.

[0021] The compostable PPE product of the present invention can be in the form of a single-use medical headgear.

[0022] In some aspects, the compostable, single-use medical shoe cover of the present invention includes a strap portion configured to be tied around the wearer's leg to securely hold the shoe cover around the wearer's shoes.

[0023] Furthermore, the single-use medical shoe cover includes a compostable drawstring configured to be pulled to tighten the shoe cover around the wearer's leg, thereby securing the shoe cover securely around the user's shoes.

[0024] In some aspects of the invention, the outer surface area of ​​the single-use medical shoe cover is roughened or dented.

[0025] In other aspects of the invention, the bottom surface area of ​​the single-use medical shoe cover is roughened or dented.

[0026] The single-use medical headgear includes a compostable pull cord that is configured to be pulled to tighten the headgear around the wearer's head, thereby securing the headgear securely around the wearer's head.

[0027] Additionally, it is envisioned that compostable PPE articles according to any of the above embodiments include compostable plant-based materials comprising compostable thistle starch-based polymers.

[0028] This disclosure also provides a method for manufacturing compostable PPE comprising compostable plant-based material. In some aspects, the compostable plant-based material includes a compostable matrix material and a compostable additive material containing a compostable sealant.

[0029] The manufacturing method includes blow molding and is achieved through the following steps: 1) Mix the compostable matrix material and the compostable additive material containing compostable sealing material at a ratio of matrix material to additive material of 95:5 to 97:3; 2) Heat the resulting mixture of compostable materials to at least between 71°C and 100°C until it melts; 3) The molten mixture is pushed through a longitudinal forming die to form a thin-walled air tube blank, wherein air is allowed to pass through a hole in the center of the die to cause the tube blank to expand, and the material is cooled by a high-speed air ring set above; 4) The expanded resin tube blank is molded into a resin sheet; 5) Use a cutting machine to cut the obtained resin sheets to form compostable PPE products.

[0030] In some aspects of the invention, the compostable matrix material and the compostable additive material containing the compostable sealant are in granular form.

[0031] In some aspects of this disclosure, compostable PPE products manufactured according to the above method are single-use medical aprons.

[0032] In other aspects of this disclosure, compostable PPE products manufactured according to the above method are single-use medical shoe covers.

[0033] In other aspects of this disclosure, compostable PPE products manufactured according to the above method are single-use medical head coverings.

[0034] In the methods described above, compostable PPE materials can be formed integrally from a single sheet of compostable material.

[0035] This compostable material can be further processed using a roll-cutting process.

[0036] Thistle-based resin is preferred because of its starch content and tensile strength properties, as well as because it does not compete with food sources and is a sustainable source.

[0037] The PPE of this invention has several advantages, with breathability being a key one. This is achieved due to the inherent properties of the bio-resin-derived material, which possesses inherent natural breathability that surpasses that of conventional PPE materials formed from low-density polyethylene (LDPE). The PPE of this invention, particularly the compostable apron, is designed with optimized combined performance, possessing sufficient fluid repellency to meet the standards required for performing the function of a splash-proof apron, while also incorporating natural fibers that allow for breathability and water vapor evaporation through the PPE material, thereby providing the wearer with the necessary comfort, as PPE is typically worn in frequently challenging hot environments, such as typical healthcare settings.

[0038] The PPE of this invention also provides a material with an appropriate weighing thickness for forming the PPE. The thickness must not exceed 16 micrometers, with a 20% margin on both sides. To achieve this, the manufacturing process of this invention includes a step of blow molding the bio-resin in a uniform manner to obtain a consistent weighing thickness. The bio-resin achieves optimal impact strength and tear resistance at a lower weighing thickness of 12 micrometers, which reduces the amount of resin required.

[0039] In addition, due to the differences in properties between bio-resin and low-density polyethylene, it has been found that specialized apron cutting machinery is needed due to the heat sensitivity of bio-resin.

[0040] Roll cutting mechanisms, rather than conventional stamping cutting techniques, provide cleaner cuts and reduce product waste because they can be effectively pulled out from the center of the die.

[0041] The PPE of the present invention has properties that meet the requirements of the Medical Device Regulation (MDR) (EU) 2017 / 745, including but not limited to water repellency, density and tensile strength.

[0042] Furthermore, the PPE according to the present invention has the advantage of meeting composting standards, including the following composting standards: EN 13430 (Recycling). EN 13431 (Energy Recovery). EN 13432 (Packaging recycling via composting and biodegradation), and ASTM 6400 (American Society for Testing and Materials (ASTM)) is a standard specification for the biodegradability (through composting) of solid materials required for the design of plastic labels for aerobic composting in municipal or industrial facilities.

[0043] Therefore, the PPE according to the present invention has a revolutionary impact on conventional thinking, in which PPE for single use requires the use of plastic materials such as LDPE to provide the performance required by PPE, including all the performance of Class 1 medical devices.

[0044] In addition, it should be noted that known studies have shown that approximately 80% of healthcare waste (HCW) is non-hazardous waste. Therefore, the inventors have surprisingly discovered that the PPE according to the present invention has another advantage: as a plant-based product, the PPE can be recycled with food waste from healthcare facilities such as hospitals after use and can be treated using anaerobic digestion (AD).

[0045] Therefore, the inventors have discovered that the PPE of the present invention has the advantage of decomposing in an environmentally friendly manner regardless of the type of waste stream in which it is disposed of. Thus, the PPE of the present invention facilitates the introduction of composting waste disposal recycling for medical waste, enabling the healthcare cycle to transition to a circular economy.

[0046] Therefore, the PPE of the present invention has a positive environmental impact and a significant positive impact on reducing the carbon footprint of healthcare.

[0047] The PPE of the present invention can be provided in various embodiments, including as a medical apron, shoe cover, and / or head covering / hairpiece. The PPE of the present invention is constructed to be comfortable to wear and suitable for proper wear by the wearer. In a healthcare environment, the PPE of the present invention functions to minimize the risk of contamination by microorganisms and hazardous liquids. Furthermore, the PPE of the present invention has the advantage of improving wearer comfort, particularly by providing a PPE material that is both breathable and provides adequate protection.

[0048] Since healthcare workers do not cause the environmental damage associated with single-use plastic items, using PPE also offers the benefits of being "guilt-free" and comfortable. Brief description of the attached figures

[0049] The embodiments of the present invention are further described below with reference to the accompanying drawings, in which: Figure 1A This is a plan view of the first aspect of the compostable single-use medical apron of the PPE of the present invention; Figure 1B This is a plan view of the medical apron of the first aspect of the PPE of the present invention during use; Figure 2A This is a side view of a second aspect of the compostable, single-use medical shoe cover of the present invention; Figure 2B This is a side view of the shoe cover in use, with the shoe inside the cover and the fastening straps perpendicular to the longitudinal plane of the shoe cover; Figure 2C This is a perspective view of the shoe cover in use, with the shoe inside the cover and the fastening straps perpendicular to the longitudinal plane of the shoe cover; Figure 2D It is a perspective view of the shoe cover in use, wherein the shoe is inside the cover and the fastening straps are parallel to and oriented toward the front of the longitudinal plane of the shoe cover; Figure 3A This is a side view of another embodiment of a second aspect of the PPE of the present invention, in the form of a compostable medical single-use shoe cover, wherein the fastening strips are parallel to the longitudinal plane of the shoe cover. Figure 3BThis is a side view of the shoe cover in use, with the shoe inside the cover and the fastening straps parallel to the longitudinal plane of the shoe cover; Figure 3C This is a perspective view of the shoe cover in use, in which the shoe is inside the cover and the fastening straps are parallel to the longitudinal plane of the shoe cover; Figure 3D It is a perspective view of the shoe cover in use, wherein the shoe is inside the cover and the fastening straps are parallel to and oriented toward the front of the longitudinal plane of the shoe cover; Figure 4A This is a side view of another embodiment of the second aspect of the PPE of the present invention, which is another alternative compostable medical single-use shoe cover with a drawstring. Figure 4B This is a side view of the shoe cover in use, with the shoe inside the cover and the drawstring loose. Figure 4C This is a perspective view of the shoe cover in use, with the shoe inside the cover and the drawstring undone; Figure 4D This is a perspective view of the shoe cover in use, showing the shoe inside the cover and secured with a drawstring; and Figure 5 This is a side view of a third aspect of the invention, in the form of a compostable, single-use medical hood, which is an alternative to the PPE of the present invention. Detailed Implementation

[0050] The PPE of this invention is compostable and is formed from a compostable starch-based polymer resin, the properties of which include, but are not limited to, water repellency, density, and tensile strength. The starch-based polymer resin also meets the WHO's criteria for biodegradable PPE options and is matched in the equivalent properties described below.

[0051] A method for manufacturing compostable starch-based biopolymer resin includes the following steps: processing a base material, preferably a thistle-based material (such as a base material sold under the trademark Mater-Bi (RTM) by Novamont), into a film sheet. Then, at least one plant-based additive is added, preferably a fluid-repellent additive, and most preferably an additive commercially available under the trademark Mater-Bi (RTM) fluid-repellent additive by Novamont. The inclusion of the fluid-repellent additive aims to reduce the penetration of fluids (the term fluids includes water, alcohol, and detergent vapors) into the film. The additives in the base material include a range of waxes and organic oils. Typically, the following ratio is used: 95% to 96% compostable matrix material, 3% to 5% compostable additive material containing compostable sealant.

[0052] Typical physical and mechanical properties of an embodiment of the base material provided by Mater-Bi (RTM) are as follows:

[0053] The PPE of the present invention is preferably formed from a combination of 97% thistle-based resin and 3% compostable fluid-repellent additive to ensure that it meets the technical requirements for appropriate water repellency, chlorine repellency and ethanol repellency—this combination has been tested to ensure the optimal balance between protection and solubility under appropriate biodigestion processes.

[0054] Thistle-based resins are preferred because of their starch content and tensile strength properties, as well as because they do not compete with food sources and are a sustainable source.

[0055] This particular resin combination was chosen to meet international composting standards.

[0056] The compostable resin is designed to meet harmonized certification standards based on current EU standards and WHO guidelines for medical PPE. Table 1 below shows the parameters tested:

[0057] The PPE of this invention has the following advantages: it meets medical technical specifications while also possessing the properties of bioresin and is suitable for blow molding and cutting techniques. Manufacturing PPE from bioresin materials presents significant challenges in cutting the material to the appropriate contour and achieving the required properties (e.g., clean edges that do not cause friction against the wearer's skin). The manufacturing process of this invention has solved these problems.

[0058] Throughout the description and claims of this specification, the words “comprise” and “contain” and their variations mean “including but not limited to”, and are not intended to exclude other parts, additives, components, elements, or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, when indefinite articles are used, this specification should be understood to consider both the plural and singular unless the context otherwise requires.

[0059] In one embodiment, the compostable starch-based biopolymer resin comprises 95% compostable matrix material and 5% compostable additive material containing compostable sealant.

[0060] In another embodiment, the compostable starch-based biopolymer resin comprises 96% compostable matrix material and 4% compostable additive material containing compostable sealant.

[0061] In another embodiment, the compostable starch-based biopolymer resin comprises 97% compostable matrix material and 3% compostable additive material containing compostable sealant.

[0062] In another embodiment, compostable starch-based biopolymer resin is formed into a medical apron designed to protect the wearer from exposure to contaminants / hazardous substances, thereby classifying it as personal protective equipment and subject to Regulation (EU) 2016 / 425.

[0063] In another embodiment, compostable starch-based biopolymer resin is formed into a medical foot cover with a resin thickness of 40 micrometers, a shoe size range of 14 to 16 inches, and is textured for slip resistance. The foot cover also complies with the European PPE Equipment Directive 89 / 686 / EEC and meets the following defect criteria for sterile options, satisfying the 4.0 AQLII level sampling protocol implemented according to MIL-std-150E standards.

[0064] In another embodiment, a compostable starch-based biopolymer resin is formed into a medical hood, wherein the resin is 30 micrometers thick, 380 to 400 mm wide, and 140 mm high. The hood has an inner fold at a distance of 40 mm from the bottom edge of the hood.

[0065] Detailed description of the attached figures Several aspects of the compostable personal protective equipment (PPE) of the present invention will now be described in more detail with reference to the accompanying drawings. Similar reference numerals denote similar features.

[0066] First aspect of the invention—compostable apron Referring first to Figure 1, which is a plan view of a first aspect of the PPE of the present invention, wherein the PPE is in the form of a compostable single-use medical apron 100. The compostable single-use medical apron 100 includes a body 102, a plurality of flexible thin strips extending from the body 102, and holes 106 located in the portion of the body 100. The compostable single-use apron 100 is formed of a compostable plant-based material containing a compostable starch-based polymer. The compostable single-use apron 100 is integrally formed from a single piece of compostable material.

[0067] The compostable PPE of the present invention is formed from a plant-based material containing a compostable matrix material and a compostable sealing material. The compostable single-use apron 100 is ideally formed by a roll-cutting process.

[0068] Now for reference Figure 1B , Figure 1B This is a first-view plan view of the compostable medical single-use apron 100 during use. The user's head is positioned in the hole 106, and the fastening strap 104 is located and secured to the user's back.

[0069] The second aspect of the invention—compostable shoe cover Now for reference Figure 2AThe image shows a side view of a first embodiment of a second aspect of the PPE of the present invention, wherein the PPE is in the form of a compostable single-use shoe cover 200. The single-use shoe cover 200 includes a body 202 and an inner sash / fold 204 configured to unfold when stretched along a transverse axis to form an unfolded space within the compostable single-use shoe cover 200 to accommodate a user's shoe. The single-use shoe cover 200 also includes a fastening strap 206 comprising two flexible, separable portions extending from the body 202. The fastening strap 206 is configured to be fastened or towards the front of each lower leg / upper ankle of the wearer to secure the single-use shoe cover around the wearer's leg, thereby holding it securely in place and preventing it from slipping off during wearer movement. The boundaries of the compostable single-use shoe cover 200 are defined by a plurality of open and sealed portions. Sealing portions 208, 210, 212, 214, and 218 prevent the user's shoe from slipping out of the shoe cover. Additionally, the inner sealing edge / fold 216 is configured to unfold when stretched along the transverse axis to form an unfolded space for accommodating the user's head. In some aspects of the invention, some or all of the outer surface area of ​​the single-use shoe cover 200 is dented and / or roughened to reduce slippage of the shoe cover 200 during use.

[0070] Now for reference Figure 2B The diagram shows a side view of the first embodiment of the second aspect in use, wherein the shoe is inside the shoe cover 200. Fastening straps 206 are arranged perpendicular to the longitudinal axis of the shoe cover and are designed to be pulled down to the operator's calf / upper ankle and secured around it, thereby ensuring that the shoe cover 200 does not detach from the shoe during use.

[0071] Now for reference Figure 2C The diagram shows a perspective view of the first embodiment of the second aspect in use, wherein the shoe is inside the shoe cover 200. Fastening straps 206 are arranged perpendicular to the longitudinal axis of the shoe cover and are designed to be pulled down to the operator's calf / upper ankle and secured around it, thereby ensuring that the shoe cover 200 does not detach from the shoe during use. Figure 2C The internal edge sealing / folding 216 is shown in its unfolded configuration to accommodate the user's shoe.

[0072] Now for reference Figure 2D The diagram shows a perspective view of the first embodiment of the second aspect in use, wherein the shoe is inside the shoe cover 200. Fastening straps 206 are arranged parallel to the front of the shoe cover's longitudinal axis and angled towards it. In use, the fastening straps are fastened around the user's calf / upper ankle to ensure that the shoe cover 200 does not detach from the shoe during use. Figure 2D The internal edge sealing / folding 216 is shown in its unfolded configuration to accommodate the user's shoe.

[0073] Now for reference Figure 3A This illustration shows a second embodiment of a second aspect of the compostable single-use shoe cover 300 of the present invention. The shoe cover 300 includes a body 302 and an inner edging / fold 304 configured to unfold when stretched along a transverse axis to form an unfolded space accommodating a user's shoe. The single-use shoe cover 300 also includes a strap portion 306 comprising two flexible, separable portions 306 extending from the body 302. The strap portions 306 are configured to fasten around each of the wearer's legs to secure the single-use shoe cover around the wearer's legs, thereby firmly holding it in place and preventing it from slipping off during wearer movement.

[0074] Now for reference Figure 3B The diagram shows a side view of the first embodiment of the second aspect in use, wherein the shoe is inside the shoe cover 300. Fastening straps 306 are arranged parallel to the longitudinal axis of the shoe cover and are designed to be pulled down to the operator's calf / upper ankle and secured around it, thereby ensuring that the shoe cover 300 does not detach from the shoe during use.

[0075] Now for reference Figure 3C The diagram shows a perspective view of a second embodiment of the second aspect in use, wherein the shoe is inside a shoe cover 300. Fastening straps 306 are arranged parallel to the longitudinal axis of the shoe cover and are designed to be fastened around the operator's lower leg / upper ankle, thereby ensuring that the shoe cover 300 does not detach from the shoe during use. Figure 3C The internal edge banding / fold 316 is shown in its unfolded configuration to accommodate the user's shoe.

[0076] Now for reference Figure 3D The diagram shows a perspective view of a second embodiment of the second aspect in use, wherein the shoe is inside a shoe cover 300. Fastening straps 306 are arranged parallel to the front of the shoe cover's longitudinal axis and angled towards it. In use, the fastening straps are fastened around the user's calf / upper ankle to ensure that the shoe cover 300 does not detach from the shoe during use. Figure 3D The internal edge banding / fold 316 is shown in its unfolded configuration to accommodate the user's shoe.

[0077] Figure 4AThis is a side view of a third embodiment of a second aspect of the compostable medical disposable shoe cover 400 of the present invention. The compostable medical disposable shoe cover includes a body 402 and a track 404 disposed around the periphery of the shoe cover 400. The track is defined by an internal space 404 formed around the upper edge of the shoe cover 400. A compostable drawstring 406 is provided, configured such that tightening the compostable drawstring 406 causes the track 404 of the shoe cover 400 to contract around the periphery of the shoe cover 400, thereby securing it around the wearer's leg and firmly holding it in place, preventing it from slipping off during wearer movement. The boundaries of the compostable disposable shoe cover 400 are defined by a plurality of open portions and sealed portions. The sealed portions 408, 410, and 412 prevent the user's shoe from slipping out of the shoe cover. In addition, the inner edge sealing / folding 414 is configured to unfold when stretched along the lateral axis to form an unfolded space for accommodating the user's shoe.

[0078] Figure 4B This is a side view of a third embodiment of a second aspect of the invention, in the form of a compostable, single-use medical shoe cover, wherein the shoe is inside the shoe cover 400. The drawstring 406 is not tightened.

[0079] Figure 4B This is a perspective view of a third embodiment of a second aspect of the use of the compostable medical single-use shoe cover of the present invention, wherein the shoe is inside the shoe cover 400. The inner seam / fold 414 has been unfolded by being tightened along the transverse axis to form an unfolded space for accommodating the user's shoe. The drawstring 406 is not tightened.

[0080] Figure 4B This is a perspective view of a third embodiment of a second aspect of the compostable medical single-use shoe cover in use of the PPE of the present invention, wherein the shoe is inside the shoe cover 400. The inner seam / folded edge 414 has been unfolded by tightening along the transverse axis to form an unfolded space accommodating the user's shoe. A drawstring 406 has been tightened such that the drawstring channel 404 of the shoe cover 400 around its periphery contracts, thereby securing it around the wearer's leg and holding it firmly in place, preventing it from slipping off during wearer movement. The drawstring 406 has been knotted to secure it in place.

[0081] The third aspect of the invention—compostable hood In a third aspect of the invention, we now refer to Figure 5The illustration shows a plan view of a third embodiment of the compostable single-use medical headgear 500 of the present invention. The compostable single-use headgear 500 includes a body 502 and a drawstring channel 504 surrounding the periphery of the headgear 500, defined by an internal space 404 formed around the upper edge of the headgear 500. A compostable drawstring 506 is provided, configured such that tightening the compostable drawstring 506 causes the drawstring channel 404 of the headgear 500 to contract around the periphery of the headgear 500, thereby securing it around the wearer's head, achieving fixation and preventing accidental movement. Additionally, an inner fold 508 is configured to fold under the body 502 of the single-use headgear 500.

[0082] Example Exemplary compositions will now be described in the following embodiments.

[0083] Example 1 In this embodiment, the method for manufacturing compostable PPE products includes the following: 95% compostable substrate material; and 5% compostable additive material containing compostable sealant.

[0084] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted; The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank; Air is forced through the hole in the center of the mold to expand the tube blank; a high-speed air ring is arranged above to cool the finished product. The expanded resin tube blank is formed into a resin sheet.

[0085] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0086] The heat generated during the cutting process by the punch can soften the bio-resin and cause uneven cuts, posing a risk of incomplete tearing from the center of the mold, thus increasing waste caused by tearing. Some embodiments of the present invention, particularly those manufactured according to Embodiment 1 above (such as...) Figure 1AThe compostable medical apron (as shown in Figure 1D) comprises a compostable starch-based biopolymer resin, which contains 95% compostable matrix material and 5% compostable additive material containing compostable sealant. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that permeate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that permeate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then rolled or pressed into large sheets. These sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0087] Testing and Test Procedures Tensile strength After conditioning at 23±2℃ for at least 24 hours, tensile tests were performed on a Lloyd TA1 physical property analyzer. The tensile tester was equipped with a 20 N force sensor and a wide vise-type clamp suitable for thin plastic specimens. A test speed of 100 mm / min and a clamp spacing of 25 mm were used. The test temperature was measured to be 23.3℃. The tensile specimens used conformed to ISO 527 Type 5 standard.

[0088] Six specimens were tested, and their dimensions were determined using digital calipers (serial number 500-196-20). Tensile strength was measured according to ISO 527, and the average of the six test specimens was taken. Each material was tested in both the transverse and machine directions.

[0089] Pants tear test After conditioning at 23±2℃ for at least 24 hours, a trouser tear test was performed on the Lloyd TA1. The sample was held with a 25mm gap between the jaws. The test speed was set to 100 mm / min until the deflection reached 150 mm.

[0090] The tensile tester was equipped with a 20 N force sensor. The test temperature was measured at 23.3°C. The machine recorded the force required to tear the specimen during each test. Each material was tested in both the transverse and machine directions.

[0091] Puncture test After adjusting at 23.5°C for at least 24 hours, a puncture test was performed on a Lloyd TA1 tensile tester. The test was conducted according to ISO 6603-2. The diameter of the puncture device was 4.26 mm.

[0092] The test speed was set at 50 mm / min until the deflection reached 20 mm. Each test material was tested in both the transverse and machine directions.

[0093] FTIR analysis FTIR measurements were performed using a Perkin Elmer Spectrum One FTIR system. Fourier transform infrared spectroscopy analysis was performed using the ATR mode of the FTIR system, with four scans per sample period at a resolution of 8 ohms. The sample scan range was 650 cm⁻¹. -1 Up to 4000 cm -1 .

[0094] Example 2 In this embodiment, the method for manufacturing a compostable apron includes the following: 96% compostable substrate material; and 4% compostable additive material containing compostable sealant.

[0095] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0096] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0097] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0098] The expanded resin tube blank is formed into a resin sheet.

[0099] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain suitable compostable PPE products.

[0100] Some embodiments of the present invention, particularly those manufactured according to Embodiment 2 (e.g.) Figure 1A The compostable medical apron (as shown in Figure 1D) comprises a compostable starch-based biopolymer resin, which contains 96% compostable matrix material and 4% compostable additive material containing compostable sealant. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that permeate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that permeate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then rolled or pressed into large sheets. These sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0101] The testing and testing procedures in Example 2 are the same as those described in Example 1 above.

[0102] Example 3 In this embodiment, the method for manufacturing a compostable apron includes the following: 97% compostable substrate material; and 3% compostable additive material containing compostable sealant.

[0103] method Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0104] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0105] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0106] The expanded resin tube blank is formed into a resin sheet.

[0107] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0108] Some embodiments of the present invention, particularly those manufactured according to Embodiment 3 (and as shown in Figure 3), Figure 1A The compostable medical apron (as shown in Figure 1D) comprises a compostable starch-based biopolymer resin, which contains 97% compostable matrix material and 3% compostable additive material containing compostable sealant. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that permeate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that permeate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then rolled or pressed into large sheets. These sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0109] The testing and testing procedures for Example 3 are the same as those for Example 1 above.

[0110] Example 4 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 95% compostable substrate material; and 5% compostable additive material containing compostable sealant.

[0111] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0112] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0113] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0114] The expanded resin tube blank is formed into a resin sheet.

[0115] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0116] Some embodiments of the present invention, particularly the compostable shoe cover manufactured according to Example 4 (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin containing 95% compostable matrix material and 5% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) through the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) through the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0117] The test and test procedure in Example 4 are the same as those described in Example 1 above.

[0118] Example 5 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 96% compostable substrate material; and 4% compostable additive material containing compostable sealant.

[0119] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0120] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0121] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0122] The expanded resin tube blank is formed into a resin sheet.

[0123] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0124] Some embodiments of the present invention, particularly the compostable shoe cover manufactured according to Example 5 (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin containing 96% compostable matrix material and 4% compostable additive material containing compostable sealing material. The additive also reduces the permeability of vapors (including water vapor, alcohol vapor, and detergent vapor) penetrating the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These rolled sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0125] The test and test procedure of Example 5 are the same as those described in Example 1 above.

[0126] Example 6 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 97% compostable substrate material; and 3% compostable additive material containing compostable sealant.

[0127] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0128] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0129] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0130] The expanded resin tube blank is formed into a resin sheet.

[0131] To ensure clean cutting, a roll cutter (or a modified punch cutter) is needed to obtain suitable compostable PPE products.

[0132] Some embodiments of the present invention, particularly the compostable shoe cover manufactured according to Example 6 above (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin containing 97% compostable matrix material and 3% compostable additive material containing compostable sealing material. The additive also reduces the permeability of vapors (including water vapor, alcohol vapor, and detergent vapor) penetrating the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These rolled sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0133] The test and test procedure of Example 6 are the same as those described in Example 1 above.

[0134] Example 7 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 95% compostable substrate material; and 5% compostable additive material containing compostable sealant.

[0135] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0136] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0137] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0138] The expanded resin tube blank is formed into a resin sheet.

[0139] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0140] Some embodiments of the present invention, particularly the compostable shoe cover manufactured according to Example 7 above (and shown in FIG. 4), comprises a compostable starch-based biopolymer resin, which comprises 95% compostable matrix material and 5% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0141] The test and test procedure in Example 7 are the same as those described in Example 1 above.

[0142] Example 8 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 96% compostable substrate material; and 4% compostable additive material containing compostable sealant.

[0143] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0144] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0145] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0146] The expanded resin tube blank is formed into a resin sheet.

[0147] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0148] Some embodiments of the present invention, particularly those manufactured according to embodiment 8 described above (and as follows) Figures 4A to 4C The compostable shoe cover (shown) comprises a compostable starch-based biopolymer resin, which contains 96% compostable matrix material and 4% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0149] The test and test procedure of Example 8 are the same as those described in Example 1 above.

[0150] Example 9 In this embodiment, the method for manufacturing compostable shoe covers includes the following: 97% compostable substrate material; and 3% compostable additive material containing compostable sealant.

[0151] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0152] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0153] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0154] The expanded resin tube blank is formed into a resin sheet.

[0155] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0156] Some embodiments of the present invention, particularly those manufactured according to FIG9 above (and as shown in Figure 9), Figures 4A to 4CThe compostable shoe cover (shown) comprises a compostable starch-based biopolymer resin containing 97% compostable matrix material and 3% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0157] The test and test procedure of Example 9 are the same as those described in Example 1 above.

[0158] Example 10 In this embodiment, the method for manufacturing a compostable hood includes the following: 95% compostable substrate material; and 5% compostable additive material containing compostable sealant.

[0159] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0160] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0161] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0162] The expanded resin tube blank is formed into a resin sheet.

[0163] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0164] Some embodiments of the present invention, particularly those manufactured according to the above-described embodiment 10 (and as follows) Figure 5 The compostable hood (shown) comprises a compostable starch-based biopolymer resin containing 95% compostable matrix material and 5% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then rolled or pressed into large sheets. These sheets have a thickness of 10 to 50 μm, and preferably 30 μm.

[0165] The test and test procedure of Example 10 are the same as those described in Example 1 above.

[0166] Example 11 In this embodiment, the method for manufacturing a compostable hood includes the following: 96% compostable substrate material; and 4% compostable additive material containing compostable sealant.

[0167] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0168] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0169] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0170] The expanded resin tube blank is formed into a resin sheet.

[0171] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0172] Some embodiments of the present invention, particularly those manufactured according to embodiment 11 above (and as follows) Figure 5 The compostable hood (shown) comprises a compostable starch-based biopolymer resin containing 96% compostable matrix material and 4% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0173] The test and test procedure of Example 11 are the same as those described in Example 1 above.

[0174] Example 12 In this embodiment, the method for manufacturing a compostable hood includes the following: 97% compostable substrate materials, and 3% compostable additive material containing compostable sealant.

[0175] method: Combine the compostable matrix material with the compostable material containing additives and heat to at least 71°C until melted.

[0176] The combined molten material is then pushed through a longitudinal forming die to form a thin-walled tube blank.

[0177] Air is forced through a hole in the center of the mold to expand the tube blank. A high-speed air ring is placed above to cool the finished product.

[0178] The expanded resin tube blank is formed into a resin sheet.

[0179] To ensure a clean cut, a roll cutter (or a modified punch cutter) is needed to obtain the appropriate compostable PPE product.

[0180] Some embodiments of the present invention, particularly those manufactured according to embodiment 12 above (and as follows) Figure 5 The compostable hood (shown) comprises a compostable starch-based biopolymer resin containing 97% compostable matrix material and 3% compostable additive material containing compostable sealing material. The additive is used to reduce the penetration of fluids (including water, alcohol, and detergents) that penetrate the compostable material of the product. The additive also reduces the penetration of vapors (including water vapor, alcohol vapor, and detergent vapor) that penetrate the compostable material of the product. The components are combined and mixed in appropriate proportions as defined above, and then formed into large sheets by rolling or pressing. These sheets have a thickness of 10 to 50 μm, and preferably a thickness of 30 μm.

[0181] The test and test procedure of Example 12 are the same as those described in Example 1 above.

[0182] Features, elements, properties, compounds, chemical parts, or groups described in connection with specific aspects, embodiments, or examples of the invention should be understood to be applicable to any other aspect, embodiment, or example described herein, unless incompatible therewith. All features disclosed in this specification (including any appended claims, abstract, and drawings), and / or all steps in any method or process disclosed herein, can be combined in any combination except for mutually exclusive combinations of at least some of such features and / or steps. The invention is not limited to the details of any of the foregoing embodiments. The invention extends to any novel feature or combination of novel features disclosed in this specification (including any appended claims, abstract, and drawings), or to any novel step or combination of novel steps in any method or process disclosed herein.

Claims

1. A compostable, biodegradable, breathable personal protective equipment (PPE) product, comprising compostable plant-based material, wherein, The compostable plant-based material comprises a compostable starch-based polymer, and wherein the compostable, biodegradable, breathable PPE meets the requirements of a Class 1 medical device according to the Medical Device Regulation (MDR) (EU) 2017 / 745.

2. The compostable, biodegradable, breathable PPE product according to claim 1, wherein, According to the definitions specified in EU standards EN13432 and ASTM 6400, the PPE is compostable, meaning that the bio-based material (plant-based material, such as starch-based material) meets the following characteristics: in a carbon dioxide-rich environment, the material degrades by at least 90% within 6 months.

3. The compostable personal protective equipment (PPE) product according to claim 1 or claim 2, wherein, The compostable plant-based material includes compostable matrix material and compostable additive material containing compostable sealing material.

4. The compostable personal protective equipment (PPE) product according to any of the preceding claims, wherein, The compostable material comprises 95 to 97 w / w% of a compostable matrix material and 3 to 5 w / w% of a compostable additive material containing a compostable sealant.

5. The compostable PPE article according to any one of the preceding claims, wherein, The compostable material has a water repellency of 948 g / m³ at 38°C. 2 / sky.

6. The compostable PPE article according to any one of the preceding claims, wherein, The compostable material has a weighing thickness of 12 to 35 micrometers.

7. The compostable PPE article according to any one of the preceding claims, wherein, The compostable material has sufficient impact strength to withstand a 30 g drop from 660 mm.

8. The compostable PPE article according to any one of the preceding claims, wherein, The compostable material has a tear resistance of 70.06 mN.

9. The compostable PPE product according to any of the preceding claims, wherein, The PPE product is in the form of a single-use medical apron.

10. The compostable PPE product according to any one of claims 1 to 8, wherein, The PPE product is in the form of a single-use medical shoe cover.

11. The compostable PPE product according to any one of claims 1 to 8, wherein, The PPE product is in the form of a single-use medical headgear.

12. The compostable PPE product according to claim 10, wherein, The single-use medical shoe cover includes a strap portion configured to be tied around the wearer's leg to securely hold the shoe cover around the wearer's shoes.

13. The compostable PPE product according to claim 10, wherein, The single-use medical shoe cover includes a compostable drawstring configured to be pulled to tighten the shoe cover around the wearer's leg, thereby securing the shoe cover securely around the wearer's shoes.

14. The compostable PPE product according to claim 10, wherein, The outer surface area of ​​the single-use medical shoe cover is roughened or dented.

15. The compostable PPE product according to claim 10, wherein, The bottom surface area of ​​the single-use medical shoe cover is roughened or dented.

16. The compostable PPE product according to claim 11, wherein, The single-use medical headgear includes a compostable pull cord configured to be pulled to tighten the headgear around the wearer's head, thereby securing the headgear securely around the wearer's head.

17. The compostable PPE article according to any one of claims 1 to 16, wherein, The compostable plant-based material comprises a compostable thistle starch-based polymer.

18. A method for manufacturing compostable personal protective equipment (PPE) as described in any of the preceding claims.

19. The method according to claim 18, wherein, The compostable plant-based material includes compostable matrix material and compostable additive material containing compostable sealing material.

20. The method according to claim 19, wherein, The manufacturing method includes blow molding, and is achieved through the following steps: 1) Mix the compostable matrix material and the compostable additive material containing compostable sealing material at a ratio of matrix material to additive material of 95:5 to 97:3; 2) Heat the resulting mixture of compostable materials to at least between 71°C and 100°C until it melts; 3) The molten mixture is pushed through a longitudinal forming die to form a thin-walled air tube blank, wherein air is allowed to pass through a hole in the center of the die to cause the tube blank to expand, and the material is cooled by a high-speed air ring disposed above; 4) The expanded resin tube blank is formed into a resin sheet; 5) Use a cutting machine to cut the obtained resin sheets to form compostable PPE products.

21. The method according to claim 20, wherein, In step 1), the compostable matrix material and the compostable additive material containing the compostable sealing material are in granular form.

22. The method according to claim 19, wherein, The compostable PPE product is a single-use medical apron.

23. The method according to claim 19, wherein, The compostable PPE product is a single-use medical shoe cover.

24. The method according to claim 19, wherein, The compostable PPE product is a single-use medical headgear.

25. The method according to claims 17 to 19, wherein, The compostable PPE can be formed from a single piece of compostable material.

26. The method according to any one of claims 17 to 19, wherein, The compostable PPE is formed by a roll cutting process.

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