Splash Resistant Facemask Layer Stiffness and Weight Balance
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Solution Overview
Problem
Existing face masks struggle to provide sufficient splash resistance while maintaining breathability, as increasing thickness or reducing pore size compromises airflow and moisture transfer, and fluorocarbon treatments raise safety and environmental concerns.
Innovation Solution
A face mask design featuring a first and second spunbond splash layer, a meltblown filtration layer, and an inner polyester cellulose wetlaid layer, all without repellent treatments, which achieves high air permeability and splash resistance through specific weight and stiffness criteria, passing ASTM F1862-05 Level 3 splash resistance testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more layers or thicker layers are added to increase splash resistance, then fluid penetration resistance is improved, but air permeability and breathability deteriorate
Solution Approach 1:
The patent changes the physical parameters of the splash layer by controlling basis weight (23.7-30.5 gsm) and drape stiffness (above 3.5) to achieve optimal balance between splash resistance and breathability without adding excessive thickness
Solution Approach 2:
The mask uses a composite structure with multiple layers including spunbond splash layers, meltblown filtration layers, and wetlaid inner layers, where each layer contributes specific properties to achieve both splash resistance and air permeability
2Reliability
If pore size is reduced to improve splash resistance, then fluid penetration resistance is improved, but air permeability and moisture transfer deteriorate
Solution Approach 1:
Different layers are assigned different local qualities: the splash layers have specific stiffness and weight properties for fluid resistance, while the inner wetlaid layer provides comfort and moisture management, allowing each zone to optimize its function
Solution Approach 2:
The patent specifies precise parameter ranges for splash layers (basis weight 23.7-30.5 gsm, drape stiffness above 3.5) to achieve the right balance between pore structure for fluid resistance and air permeability for breathability
3Reliability
If fluorocarbon treatments are applied to enhance splash resistance, then fluid penetration resistance is improved, but safety and environmental compatibility deteriorate
Solution Approach 1:
The patent removes fluorocarbon treatments from the mask construction entirely, achieving splash resistance through the physical structure and properties of the spunbond and wetlaid layers without harmful chemical coatings
Solution Approach 2:
The mask uses disposable nonwoven layers with inherent splash resistance properties that do not require persistent chemical treatments, aligning with safer, treatment-free medical PPE
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 effectively resists fluid penetration while maintaining breathability, absorbing more fluid and reducing interaction with the filter layer, ensuring comfort and safety without using fluorocarbon treatments.
Implementation Method 1
The challenge in providing splash resistance to face masks is to maintain an acceptable level of breathability while prohibiting splashes as well as minute airborne (virus) particles from passing through the mask
Implementation Method 2
Fluorochemical repellents are unique in that they confer both water and low surface tension fluids repellent to fabrics. This property is important because blood and alcohol, common liquids in an operating room, are low surface tension liquids.
Implementation Method 3
a meltblown filtration layer (24) and an inner layer (22) suitable for contact with the wearer's face
Implementation Method 4
the heat and moisture from expired air creates micro-climates between the exterior of the mask and the covered skin
Data Source
Figure 1~2
AI summary
There is provided a splash resistant facemask having two outer splash layers adjacent each other on a side away from a wearer, a filter layer and an inside layer. None of the layers contains a repellent treatment. The facemask can pass a fluid splash resistance test, e.g. ASTM F-1862-05, wherein fluid is directed at the mask at a pressure of 160 mmHg.