Development of reusable cloth mask with nanoparticle filtration efficiency greater than 95%

After the rapid spread of SARS-Cov-2 virus, the use of masks was suggested by the world health organization (WHO) to reduce the virus transmission, whose primary mode of transmission was suggested to be through respiratory droplets. The recommended face coverings were single use surgical and respirator masks made of non-woven materials. With the increased demand for masks worldwide, the environmental impacts of mask disposal and the pollution caused by microplastic fibers of the non-woven materials were presented. This challenge necessitates the need for the development of a novel reusable mask reducing the environmental effects, while providing the necessary personal protective properties. Based on the ASTM F2299 standard test method, the performance, i.e., particle-size dependent filtration efficiency and pressure drop were studied for 20 samples with multilayer knit fabrics of natural and synthetic fibers (inner layer of pure cotton, cotton-nylon and cotton-polyester, middle layer of Lycra, and outer layer of superhydrophobic polyester). The results show that all the samples had an efficiency of >94% and 87-99% for large (250 nm-1 mu m) and small (100-250nm) particles, respectively. The best performing structure has a material composition of 41% superhydrophobic polyester, 26% natural cotton, 24% nylon and 9% Lycra. The filtration efficiency, pressure drop, and quality factor for this sample are 97.8% (for 100 nm particles), 4.04 mmH(2)O/cm(2) and 4.77 kPa respectively. It was also demonstrated that the developed mask maintains its performance after 50 wash/dry cycles, verifying its reusability. It should be noted that charge neutralizer was not used in the experimental setup of this study which might have led to enhanced results for the filtration efficiency of small (100-250nm) particles due to the dominance of electrostatic attraction. However, several samples were tested by the third-party company who uses a certified testing equipment based on ASTM F2299, and similar results were obtained.

Automated summary

After the rapid spread of SARS-Cov-2 virus, the use of masks was suggested by WHO to reduce transmission. However, the disposal of masks and the pollution caused by non-woven materials are concerning. This study developed a reusable mask with multilayer knit fabrics, showing high filtration efficiency and pressure drop. The mask maintained its performance after 50 wash/dry cycles, indicating its reusability.