Electrospun Mask Filter with Hydrophobic Layer for Moisture Resistance
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Solution Overview
Problem
Conventional masks with thick nonwoven filters are uncomfortable to wear due to high inhalation resistance and lose filtering efficiency when wet, as they rely on electrostatic charges that are ineffective in moist environments, failing to block pathogens like SARS and coronavirus.
Innovation Solution
A mask with a thin filter layer made of electrospun fine fibers on a mesh support layer, which maintains filtering efficiency even when wet by using a web of fine fibers and a water-repellent face contact member with through-holes for drainage, reducing inhalation resistance and preventing pathogen inhalation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick nonwoven filter is used to block contaminants, then filtering efficiency is improved, but inhalation resistance increases making breathing uncomfortable
Solution Approach 1:
The filter is segmented into multiple functional layers: a melt-blown nonwoven layer for electrostatic filtration, a hydrophobic membrane layer for liquid repellency, and a support layer for structural integrity. This segmentation allows each layer to perform its specific function optimally without requiring excessive thickness, thereby maintaining low breathing resistance while achieving high filtration efficiency.
Solution Approach 2:
The mask employs a composite structure combining different materials with complementary properties: electrostatic nonwoven fabric for particle capture, hydrophobic polyolefin membrane for liquid resistance, and porous support material for mechanical strength. This composite approach enables the filter to achieve both high contaminant blocking efficiency and low inhalation resistance through the synergistic effects of multiple materials.
2Reliability
If electrostatic nonwoven fabric is used for filtering, then blocking efficiency against fine contaminants is excellent, but filtering function is lost when the mask gets wet
Solution Approach 1:
A hydrophobic membrane layer is placed between the electrostatic nonwoven filter layer and the external environment to prevent water from reaching and damaging the electrostatic charges. This preliminary protective action ensures that the electrostatic filtration mechanism remains effective even in humid or wet conditions, as the hydrophobic layer blocks water penetration before it can neutralize the electrostatic charges.
Solution Approach 2:
The combination of electrostatic nonwoven fabric and hydrophobic membrane creates a composite filter system where the hydrophobic material protects the electrostatic properties from moisture. The hydrophobic layer repels water while allowing air and particles to pass through, preserving the electrostatic charging mechanism's effectiveness in various humidity conditions.
3Reliability
If a thick mask body is used to maintain shape and filter contaminants, then filtering performance is improved, but water particles block fine pores making it difficult to breathe when wet
Solution Approach 1:
Different regions of the mask body have different properties optimized for their specific functions: the electrostatic nonwoven layer provides filtration, the hydrophobic membrane provides liquid repellency with larger pores that prevent water blocking, and the support layer provides structural maintenance. This local differentiation allows the mask to maintain both filtration performance and breathing ease when wet, as each layer performs its specialized function without compromising the others.
Solution Approach 2:
The mask utilizes porous materials with carefully controlled pore structures: the electrostatic nonwoven layer has fine pores for particle capture, while the hydrophobic membrane has larger pores that allow air flow but repel water through surface tension effects. This hierarchical porous structure enables the mask to maintain breathing ease when wet while preserving filtration performance through the combination of different pore sizes and materials.
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 mask provides low inhalation resistance and maintains high filtering efficiency against contaminants and pathogens, even in moist conditions, allowing continuous wear without compromising breathing or filtering performance.
Implementation Method 1
fine contaminants contained in the air are adsorbed by the above-mentioned static electricity when air passes through the mask body
Implementation Method 2
a filter member that consists of a support layer having a mesh structure and a filter coating layer formed on one side surface of the support layer to filter contaminants
Implementation Method 3
a water-repellent face contact member with through-holes for drainage
Data Source
AI summary
The present invention relates to a mask comprising a mask body for covering a wearer's face and wearing straps coupled to both sides of the mask body, the mask body comprising a filter member having: a support layer having a mesh structure; and a filter coating layer formed on the outer surface of the support layer and for filtering contaminants, wherein the filter coating layer is formed from a microfiber web eletrospinned on the support layer.