Reusable Face Mask with Microfilament Layers
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Solution Overview
Problem
There is a need for a reusable and washable medical face mask that maintains filtration efficiency, breathability, and microbial cleanliness, as existing germicidal face masks are not washable or reusable, leading to shortages during pandemics.
Innovation Solution
A face mask with multiple layers of non-woven polyester/polyamide microfilaments, treated with a germicidal agent, that is washable and reusable, maintaining compliance with medical standards EN 14683:2019+AC:2019 and ASTM F2100 - 19e1, while ensuring high filtration efficiency and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a face mask is treated with a germicidal agent, then microbial cleanliness is improved, but washability and reusability deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and structure of the mask layers to enable washability while maintaining germicidal activity. The non-woven fabric is treated with germicidal agents in a way that allows the mask to be washed multiple times (at least 50 times) while retaining its germicidal properties, thus changing the durability parameter of the germicidal function.
Solution Approach 2:
The patent uses composite materials by combining non-woven fabric with germicidal agents in a multi-layer structure. The mask comprises an outer layer, inner layer, and intermediate layer, where germicidal agents are integrated into the fabric structure through impregnation or coating, creating a composite material that maintains both filtration efficiency and germicidal activity after repeated washing.
2Productivity
If a face mask is made reusable and washable, then productivity is improved, but filtration efficiency may deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the porosity and fiber structure of the non-woven fabric to maintain filtration efficiency after repeated washing. The mask is designed to withstand at least 50 wash cycles while maintaining its filtration performance, thus changing the durability parameter of the filtration function.
Solution Approach 2:
The patent uses porous materials by employing non-woven fabric with controlled porosity that allows air passage while filtering particles. The porous structure is designed to remain stable after repeated washing, maintaining both breathability and filtration efficiency throughout the mask's reusable life cycle.
3Reliability
If a face mask has high filtration efficiency, then reliability is improved, but breathability deteriorates
Solution Approach 1:
The patent applies local quality by creating different functional zones within the multi-layer mask structure. The outer layer provides germicidal activity and particle filtration, the intermediate layer provides additional filtration, and the inner layer ensures comfort and breathability against the wearer's skin. Each layer is optimized for its specific function, achieving both high filtration efficiency and good breathability.
Solution Approach 2:
The patent uses composite materials by combining multiple non-woven fabric layers with different porosity and filtration characteristics. This composite structure allows the mask to achieve high filtration efficiency through the outer and intermediate layers while maintaining breathability through the optimized inner layer, thus resolving the contradiction between filtration and breathability.
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 face mask achieves bacterial filtration efficiency greater than 95%, viral filtration efficiency greater than 75%, and breathability of 50 Pa/cm² or less, with the germicidal agent remaining effective after multiple washes, allowing for at least 50 times reusability without significant loss of performance.
Implementation Method 1
The body portion is comprised of a plurality of layers super-imposed on each other, said body portion comprises at least two layers of non-woven web
Implementation Method 2
said face mask is provided with a germicidal agent, thereby also ensuring that the mask kills or inhibits bacteria and/or viruses
Implementation Method 3
The porosity of the mask refers to how easily air is drawn through the mask and a more porous mask is, of course, easier to breathe through
Data Source
AI summary
The current invention relates to a face mask comprising a body portion configured to be placed over a mouth and at least part of a nose of a user, wherein said body portion is comprised of a plurality of layers super-imposed on each other, said body portion comprises a least two layers of non-woven web, characterized in that said non-woven web having a weight of between 20 and 50 g/m2 and is comprised of polyester/polyamide microfilaments, having a diameter of less than 5 micron.