Biodegradable Cellulose Filter Media for Sustainable Facial Masks
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Solution Overview
Problem
Current disposable facial masks rely on melt-blown filter layers made from non-biodegradable synthetic polymers, which are unsustainable and face production capacity limitations, while paper-based alternatives struggle to meet requirements for breathability, bacterial filtration efficiency, and mechanical strength.
Innovation Solution
A biodegradable cellulose-based filter media comprising at least 50 wt % refined cellulose fibers, manufactured via a wet-laid process, which balances breathability and filtration efficiency, and can be used in facial masks, offering high biodegradability, compostability, and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If melt-blown process technology is used to manufacture filter layers, then filtration efficiency is achieved, but production capacity is limited and materials are non-biodegradable
Solution Approach 1:
The patent changes the material parameter from synthetic polypropylene to natural cellulose fibers, and changes the manufacturing parameter from melt-blown process to wet-laid papermaking process. This enables high-speed production (1000-2000 meters per minute) while achieving biodegradability and compostability of the filter layer
Solution Approach 2:
The patent employs a disposable filter layer made from cellulose fibers that can be rapidly produced and then discarded after use. The wet-laid process enables economical high-volume production of single-use masks, and the biodegradable nature ensures environmental compatibility after disposal
2Object-generated harmful factors
If paper-based materials are used for filter media, then biodegradability is improved, but breathability and bacterial filtration efficiency are insufficient
Solution Approach 1:
The patent applies different refining degrees to different regions of the fiber network. Highly refined cellulose fibers create dense regions for filtration, while less refined areas maintain porosity for breathability. This local variation in fiber treatment enables simultaneous achievement of BFE ≥95% and breathability
Solution Approach 2:
The patent creates a composite structure within the cellulose fiber matrix by combining fibers of different refinement levels and potentially different cellulose sources. This composite approach allows the material to exhibit both filtration efficiency (from refined regions) and breathability ( from less refined regions) while maintaining biodegradability
3Object-generated harmful factors
If paper materials are used for filter media, then biodegradability is improved, but mechanical strength is insufficient
Solution Approach 1:
The patent applies preliminary refining treatment to cellulose fibers before forming the filter layer. This pre-refining process modifies fiber surface properties and enhances fiber-to-fiber bonding capacity, resulting in improved mechanical strength (tensile strength ≥10 N/cm) while maintaining biodegradability of the final product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cellulose-based filter media provides excellent bacterial and particle filtration efficiency while maintaining breathability, is lightweight, and can be easily manufactured in high volumes, addressing the sustainability and production challenges of existing masks.
Implementation Method 1
wet laying and draining at least two furnishes of cellulose fibers onto a screen assembly to form a web
Data Source
AI summary
A cellulose-based filter media (10) is disclosed having a first phase (14) and a second phase (16), wherein the first phase (14) includes refined cellulose fibers, and wherein the second phase (16) includes cellulose fibers along with at least one of cellulose-based man-made fibers or non-cellulose man-made fibers. A facial mask (18) having the filter media (10) and a process for making the filter media (10) are also disclosed. Due to the composition of the filter media (10), the filter media (10) and/or facial mask (18) incorporating the same are at least partially biodegradable, compostable, and/or recyclable and can be formed from a wet laid process.