Reusable Knit Face Mask with Multifilament Yarn
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Solution Overview
Problem
Current medical masks, including surgical and respiratory masks, are not reusable and contribute to significant waste due to their single-use nature, and barrier masks have variable filtration performance.
Innovation Solution
A reusable mask with a tubular knitted fabric design featuring synthetic multifilament yarns for improved filtration and durability, allowing for washing at high temperatures to neutralize infectious agents while maintaining filtration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surgical masks or respiratory masks are used, then filtration performance is achieved, but the masks must be replaced every 3-4 hours and are not reusable
Solution Approach 1:
The patent changes the material parameters by using knitted fabric with specific loop structures and synthetic multifilament yarns instead of traditional non-woven materials. This allows the mask to withstand repeated washing at high temperatures (60°C) while maintaining filtration performance, transforming the mask from single-use to reusable
Solution Approach 2:
The mask combines different materials with complementary properties: knitted fabric for durability and reusability, synthetic multifilament yarns for filtration, and elastic fibers for fit. This composite structure enables both high filtration efficiency and multiple reuses through washing
2Object-affected harmful factors
If barrier masks are made by hand, then they provide protective barrier, but filtration performances are very variable and unsatisfactory
Solution Approach 1:
The patent replaces the manual assembly process with an automated knitting process that creates the mask in one continuous operation. The knitting machine precisely controls yarn placement, loop structure, and fabric density, ensuring consistent filtration performance across all masks without manual intervention
Solution Approach 2:
The knitting process allows precise control of structural parameters including loop size, yarn tension, and fabric density. By optimizing these parameters during knitting, the patent achieves consistent high filtration performance (bacterial filtration efficiency ≥95%) across all produced masks
3Reliability
If non-woven fabric is used for masks, then they provide filtration, but they generate significant waste due to single-use nature
Solution Approach 1:
The patent enables recovery and reuse of the mask through repeated washing at 60°C, which neutralizes infectious agents while maintaining the structural integrity and filtration capacity of the knitted fabric. This transforms the mask from a disposable item to a reusable protective device
Solution Approach 2:
The patent changes the material composition to include heat-resistant synthetic fibers and robust knitted structures that can withstand high-temperature washing cycles. This allows the mask to be recovered and reused multiple times, significantly reducing waste compared to single-use non-woven masks
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 consistent filtration performance, reduces waste by being reusable, and maintains respiratory comfort with low inspiratory resistance.
Implementation Method 1
the knit in the filtering zone is a knit of at least one synthetic multifilament yarn in rows, each synthetic multifilament yarn comprising at least seven filaments in the filtering zone
Implementation Method 2
allows the mask to be washed at a temperature high enough to neutralize an infectious agent, for example 60°C, while maintaining the filtration capabilities of the filtering area
Data Source
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AI summary
The invention relates to a mask (10) comprising a main body (12) in turn comprising two end parts (18) and a central portion (20) including a filtering region (32). The main body (12) is a tubular-shaped knit fabric. Each end part (18) has a slot extending over a portion of the circumference of the tubular shape and defining a strap (30) suitable for placing around the ear. The knit fabric in the filtering region (32) is a knit fabric comprising at least one synthetic multi-filament yarn in courses, each synthetic multi-filament yarn comprising at least seven filaments. Said knit fabric has a stitch length of less than or equal to 0.35 centimetre per needle. For each course the at least one synthetic multi-filament yarn forms one stitch at least every other wale. The invention also relates to an associated manufacturing process.