Two-Layer FFP2 Mask Structure for Filtration and Breathability

Solution Overview

Problem

Existing FFP2-type face masks require multiple layers of nonwoven fabric to achieve desired filtration and breathability, leading to bulkiness and discomfort, while two-layer configurations fail to meet filtration efficacy standards.

Innovation Solution

A face mask composed of two layers: a meltblown polypropylene layer bonded with a spunbond polypropylene layer via thermal fusion, achieving a density of 0.90-0.96 kg/dm³ and a thickness of 0.5 mm, ensuring EN149 standard filtration performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple layers of nonwoven fabric are used to achieve desired filtration and breathability, then filtration efficacy is improved, but mask thickness and weight increase leading to bulkiness and discomfort

Engineering Contradiction:

Improvefiltration efficacyVSAvoidmask weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention merges the filtering function and breathing function into a single integrated nonwoven fabric layer. The fabric combines hydrophobic properties for filtration with hydrophilic properties for breathability, eliminating the need for multiple separate layers while maintaining both functions effectively.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses a composite nonwoven fabric structure combining different fiber types and properties within a single layer. The fabric integrates hydrophobic fibers for particle filtration and hydrophilic fibers for moisture management, creating a multifunctional material that replaces traditional multi-layer configurations.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple layers of nonwoven fabric are used to achieve desired filtration and breathability, then filtration efficacy is improved, but mask thickness increases leading to bulkiness and discomfort

Engineering Contradiction:

Improvefiltration efficacyVSAvoidmask thickness

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The invention merges the filtering function and breathing function into a single integrated nonwoven fabric layer. The fabric combines hydrophobic properties for filtration with hydrophilic properties for breathability, eliminating the need for multiple separate layers while maintaining both functions effectively.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses a composite nonwoven fabric structure combining different fiber types and properties within a single layer. The fabric integrates hydrophobic fibers for particle filtration and hydrophilic fibers for moisture management, creating a multifunctional material that replaces traditional multi-layer configurations.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If two-layer configuration is used to reduce mask thickness and weight, then ergonomic comfort is improved, but filtration efficacy may be compromised

Engineering Contradiction:

Improveergonomic comfortVSAvoidfiltration efficacy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention uses a composite nonwoven fabric structure combining different fiber types and properties within a single layer. The fabric integrates hydrophobic fibers for particle filtration and hydrophilic fibers for moisture management, creating a multifunctional material that replaces traditional multi-layer configurations.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the physical and chemical parameters of the nonwoven fabric by controlling fiber diameter distribution, fiber composition ratios, and fabric density. These parameter adjustments enable a single layer to achieve both high filtration efficacy and good breathability, meeting FFP2 standards while maintaining comfort.

Inventive Principle:

Principle #35Parameter changes

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 two-layer configuration enhances filtration efficacy and breathability, reducing mask thickness and weight, while maintaining ergonomic comfort and aesthetic appeal.

Implementation Method 1

a meltblown polypropylene layer bonded with a spunbond polypropylene layer via thermal fusion

Methodology Applied

Scientific EffectThermal fusion: Heating

Data Source

PatentEP4292670B1FFP2-type filter face masks with two layers

Publication Date: 2025.11.26 IDEE INNOVATIVE SRL

AI summary

The object of the present invention is the preparation of an FFP2NR-type mask made up solely of two layers of meltblown nonwoven fabric with high filtering power bonded through thermal fusion with a layer of spunbond fabric.