Polypropylene Spunbond Non-Woven Stuff for COVID Mask Filters | Where to get it

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For COVID-19 prevention, adding a third layer to cotton face masks is now suggested. The material of choice for this third layer is polypropylene spunbond non-woven stuff, but many people are unfamiliar with it or where to find it. Here’s all you need to know about the WHO latest guidelines, which include masks produced at home and by local apparel firms.

Every study that has looked into layering in face masks has concluded that adding more layers increases filtration, however certain textiles produce better filtration than others. We agree with the public health suggestion and recommend that washable cloth masks employ industry-grade spunbond polypropylene as an intermediate layer.

Spunbond polypropylene for the apparel and furniture sectors has a fabric-like texture. It’s machine washable and won’t divert medical-grade polypropylene from official PPE production. The research team aims to develop cloth masks for community usage by combining skills in epidemiology, chemistry, textiles, and the mask business.

Variety of pp spunbond non-woven fabric

Non-woven fabrics have a random distribution of fibres, similar to spaghetti on a plate. This randomization allows for strong particle filtering while maintaining a high level of airflow.

Spunbond non-woven comes in a variety of forms. Spunbond, meltblown, and spunlace materials are the most frequent. The randomly oriented fibres in certain spunbond polypropylene fabric are crushed and fused in a pattern of tiny, closely spaced welds known as point bonds.

The outer layers of three-layer certified medical masks are made of lightweight medical-grade spunbond polypropylene fabric that has been customized for medical purposes. It is not meant to be cleaned because it is a single-use material. It’s one of the various interfacing fabrics used to add support to waistbands, collars, and zippers. It’s also used to keep the bottoms of sofas and chairs clean. Because it is not part of the supply chain for personal protective equipment, it is widely available through fabric wholesalers and is not currently in limited supply. This information is most likely in line with public health guidelines.

Suggested material

We recommend utilizing industry-grade pp spunbond non-woven fabric for community masks. Spunbond nonwoven is available in single and double layers, depending on the manufacturer. Although there are limited available statistics on its filtration qualities, we recommend choosing a fabric with a 68 gram per square meter rating, or two layers of less dense fabric.

When creating masks, the material can be used as an intermediate layer.

Alternatively, between the two outer layers of a fabric mask, a rectangle of spunbond polypropylene can be put. The fabric is not readily frayed. To build a washable filter out of two layers of polypropylene, fold the material in half and sew it together with a basic stitch or an overlock.

The polypropylene may be cleaned according to WHO guidelines, which include a hot wash with detergent. Non-woven spunbond fabric is washable. It should not be tumble dried; instead, it should be taken out and hung or set flat to dry before replacing it. It is not recommended to iron it since it is made of plastic and would melt.

These materials are available in quantity from fabric wholesalers, who are attempting to bring them to retailers. Mask creators may anticipate seeing their products in shops.

Inappropriate materials

It’s crucial to understand that not all interface is made of polypropylene. Polyester or polyester-rayon mixes are used in many brands. This is a wholly distinct type of substance. Interfacing is occasionally offered as a fusible product in the retail sector. This implies it’s been pre-glued to aid in precise positioning before being sewn in place. Because the glue may compromise filtration and breathability, these pre-glued materials should not be used for face coverings.

Some spunbond reusable shopping bags feature a gleaming plastic finish. These aren’t breathable and should be avoided at all costs. Many approved medical masks and respirators such as N95s employ melt-blown polypropylene as the intermediate layer since it filters extremely efficiently. It is still in low supply, with several distributors completely committed until July 2021. It is not designed to be cleaned, yet new programmes allowing limited respirator reuse have been developed.

We do not propose utilising melt-blown polypropylene for reusable non-medical masks because of a lack of availability and the fact that it is not washable.

Commercially available disposable non-medical filters for use in pocket masks may comprise meltblown, spunbond, and other components; it is not always feasible to discern their composition from packaging or ads. There are currently no guidelines governing their use. They’re made to be thrown away after each usage.

Spunlace polypropylene is inherently elastic, and unlike spunbond and melt-blown polypropylene, it absorbs liquids. Spunlace techniques are used to make some wet wipes. To boost absorbency, the material used is generally a viscose-polyester blend rather than polypropylene. The composition of the wet components is clearly stated on the box, however, the fiber composition of many wipes is not. These items aren’t designed to be washed and reused. Some wipes include active chemicals that, if breathed, might be hazardous. We do not advocate utilizing dried-out wipes as filters for all of these reasons.

PP spunbond non-woven fabric is a continuous material that is pierced fully by thousands of tiny needles on a roller. Without fibers protruding into the gap, these perforations provide a low-resistance channel for airflow. We don’t endorse them since we believe they will filter badly.

Imperfect does not prove ineffectiveness

The ineffective use of defective masks has the potential to aid in the containment of COVID-19 dissemination. Mask regulations have resulted in significant reductions in transmission when utilizing the masks now available. The industry is attempting to increase the availability of polypropylene textiles in response to the new rules.

We expect to be able to use typical industry descriptors like material type and weight to define fabrics that are likely to filter effectively and be breathable.

FAQs

What materials are needed to make masks for the coronavirus disease?

Three layers of fabric should be used to make fabric masks:

Cotton or other absorbent material or spunbond fabric is used as the inner layer.

Non-woven, non-absorbent material, such as polypropylene, in the middle layer.

Non-absorbent outer layer, such as polyester or a polyester mix or Non Woven Fabric.

During COVID-19, may I use masks with exhalation valves?

Vents or exhalation valves on masks are not recommended since they enable unfiltered air to escape.