FREQUENTLY ASKED QUESTIONS
Melt Blown extrusion is a production process used to create a type of fabric called non-woven fabric made from polymers such as polypropylene.
Traditional fabrics made from natural materials such as cotton are woven together, meaning the material is first transformed into a yarn, then transformed to form a fabric thread layer in a weaving or knitting process. The resulting fabric has a number of desirable properties, including:
• Bacterial barrier
• Flame retardancy
• Liquid repellency
Non-woven fabrics do not contain yarn weaving or splicing; It is produced from other separate melted polymer fibers in a net-like fabric by mechanical, thermal or bonding processes.
• Non-woven fabrics are used in various applications, creating products used in agriculture, automotive, construction, personal hygiene, roofing, carpet, upholstery and medical products. Specific examples of product types that can be manufactured using nonwoven fibers include:
• Filtration, such as HEPA air filters or liquid and gas filter products
• Masks and respirators for medical and industrial use
• Disposable medical garbs, such as gowns, drapes, shoe coverings, and head coverings
• Sanitary products, such as those for feminine hygiene and disposable diapers
• Oil and liquid adsorbents, which are products that contain spills and pick up oil from the water
• Coffee filters and tea bags
• Artificial turf
• Insulating products
• Meat and vegetable packing trays
• Disposable disinfectant wipes
Medical masks typically are created from stacking together three layers of non-woven material. An inner layer that comes in contact with the wearer’s face is used to absorb moisture that is created during normal expiration. An outer layer of non-woven fabric serves as a waterproof barrier that precludes any liquids expelled by the patient while talking, coughing, or sneezing from being transmitted or absorbed by the mask. Sandwiched between the inner and outer layer of the mask is a middle layer that serves as a filter. This middle layer is usually created from polypropylene (PP) melt-blown non-woven fabric and is treated to be an electret. The electret treatment adds electrostatic properties to the filter layer allowing for electrostatic adsorption which helps to trap aerosolized particles via electrostatic attraction.
Mask making machinery used to rapidly create disposable medical masks automates the steps needed in the process. The basic process steps for creating flat disposable medical or surgical masks are:
• 1. Combining the three layers of materials together to produce the multilayer mask fabric – The machine takes the different non-woven fabrics from their supports and feeds them together into a layered structure.
• 2. Attachment of the metal nose strip – the machine stitches the flat metal wire onto the 3-layer fabric which will be used by the wearer to fit the mask to their nose and improve its seal to the face.
• 3. Add folds and pleats – the machine uses a folding device to add folds and pleats to the mask that will enable a standard mask to be adjusted to suit different wearers.
• 4. Cutting & stitching – the three-layer material is cut to individual size masks and the edges are stitched to join the layers.
• 5. Attachment of ear loops – ear rope is attached, and adhesive is applied, followed by a thermal press to secure the loops in place. Other methods of attachment include the use of ultrasonic welding. (Our production is fully ultrasonic.)
• 6. Disinfection – medical-grade masks are subjected to a sterilization process using ethylene oxide to render any microbial contamination inactive. Following this treatment, masks must be allowed to stand for a period of 7 days until the ethylene oxide level dissipates, as the material is toxic to the human body as well as being flammable.
• 7. Packaging – following the waiting period, completed masks are packaged for shipment.
No. Although medical alcohol can effectively neutralize viruses, it also destroys the hydrophobic purification process of the surface layer of the mask during the process and reduces the filtering effect of the mask.
In public areas, masks should be worn once a day and ideally the duration of use should not exceed 4 hours.
The filter performance of the mask is determined by the filter material in the middle layer. Generally, the filter material is a non-woven, very thin polypropylene fabric. It can filter fine, breathable and efficient. Thin, comfortable to breathe and can filter efficiently.
Our surgical masks are sold in packages of 50 pieces.
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