Liquid Spray Formulation for Face Masks
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Solution Overview
Problem
Current face masks, especially those pre-coated with anti-viral agents, face challenges in scalability, uniform coating, stability, and effectiveness against enveloped respiratory viruses like SARS-CoV-2, due to manufacturing complexities and rapid degradation issues.
Innovation Solution
A liquid formulation comprising an anionic surfactant, an organic acid (such as citric acid), and a film-forming polymer, which is sprayed onto a face mask to create a hydrated matrix, providing antiviral and antibacterial properties, is introduced. This formulation has a pH range of 2.5 to 4, ensuring even distribution and long-lasting efficacy up to 12 hours without the need for separate manufacturing lines or pre-coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-coating processes are used to apply anti-viral agents on face masks, then antiviral effectiveness is improved, but manufacturing complexity and device complexity increase
Solution Approach 1:
The invention separates the antiviral treatment from the mask manufacturing process. Instead of pre-coating masks during manufacturing, the antiviral formulation is applied separately by the end user through spray application, thereby simplifying manufacturing while maintaining antiviral effectiveness.
Solution Approach 2:
The formulation is designed to be self-applied by the user without requiring specialized manufacturing equipment or processes. The user sprays the formulation directly onto the mask, making the system self-servicing and eliminating complex pre-coating infrastructure.
2Reliability
If pre-coating processes are used to apply anti-viral agents on face masks, then antiviral effectiveness is improved, but uniform coating and stability are worsened due to rapid degradation
Solution Approach 1:
The formulation uses a low pH range (2.5-4.0) maintained by organic acids to enhance stability and prevent degradation of the antiviral agents. This parameter optimization ensures the formulation remains effective throughout its shelf life and during use.
Solution Approach 2:
The formulation combines multiple components including organic acids (citric, malic, lactic, or tartaric acid), film-forming polymers, and anionic surfactants in a synergistic composite system. This composite structure provides both stability during storage and effective antiviral activity upon application.
3Ease of operation
If spray application is used to apply formulation on face masks, then ease of operation and scalability are improved, but manufacturing precision and coating uniformity are worsened
Solution Approach 1:
The spray formulation is designed for self-application by the user, eliminating the need for precision manufacturing equipment. The user can easily spray the formulation onto the mask surface, achieving sufficient uniformity for effective antiviral protection without requiring controlled manufacturing conditions.
Solution Approach 2:
The formulation is designed to achieve homogeneous distribution of active ingredients across the mask surface through spray application. The liquid formulation ensures even coverage and uniform deposition of antiviral agents, achieving sufficient homogeneity for effective protection.
4Reliability
If anionic surfactants and organic acids are used in the formulation, then antiviral effectiveness against enveloped viruses is improved, but potential harmful effects on skin and mask materials worsen
Solution Approach 1:
The formulation carefully controls the pH within the range of 2.5-4.0 and optimizes the concentrations of anionic surfactants and organic acids to achieve effective antiviral activity while minimizing potential harmful effects on skin and mask materials.
Solution Approach 2:
The formulation is applied locally on the mask surface rather than being in direct contact with skin for extended periods. The antiviral action occurs on the mask material where enveloped viruses are inactivated, reducing potential irritation to the wearer's skin.
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 formulation effectively reduces viral titers by over 99.9% on various mask materials within 10 to 30 minutes, maintaining antiviral efficacy for up to 12 hours, and is cost-effective, scalable, and user-friendly, with no corrosive effects on mask materials or skin irritation.
Implementation Method 1
anionic surfactant
Implementation Method 2
an organic acid selected from a list consisting of citric acid, malic acid, lactic acid and tartaric acids, the pH of the formulation being between 2.5 and 4
Implementation Method 3
a film forming polymer
Data Source
AI summary
The present invention relates to a liquid formulation for spraying on a face mask, the formulation being an aqueous solution having a pH in a range between 2.5 and 4 and comprising an organic acid selected from a list consisting of citric acid, malic acid, lactic acid and tartaric acids, a film forming polymer, and an anionic surfactant. Other aspects of the invention are the use of such a liquid formulation to spray it on a face mask, and a method of forming a film on a face mask.