During the Covid 19 pandemic, face masks have become the topic of everyday conversation and have been mass produced in volume and sold across the world.
Every company is trying their hardest putting forward various production techniques in order to manufacture a compliant, high quality mask that can cope with Covid19.
From all the techniques seen, Meltblown is the process which has gained quite an interest in the mask making industry.
What is Non Woven Meltblown?
Melt Blown is a non woven manufacturing system.
It is manufactured conventionally by converting polymers into non woven microfilaments.
With the help of melt blowing process, two layers of different fabrics are combined and woven together.
The fibres are combined in a process of tangling and sticking together at speed.
What are Layers in a Face Mask?
Polypropylene is the material that is melt blown to produce Surgical or Medical face masks and respirator masks.
Face masks essentially consist of three layers; outer, middle, and inner.
It is the middle layer, which is primarily made up of melt blown polypropylene.
Melt blown filter is a high efficiency particulate air (HEPA) filter and is commonly used for PPE face masks and respirators.
With its ability to block approximately 95 percent of particles, splashes, and splatters, it can filter out airborne particles as small as 0.3 microns, including infectious pathogens, vapours, fumes, and dust.
The melt blown filter material's high BFE percentage makes it an essential component of PPE face masks and respirators for providing effective protection against airborne contaminants.
Advantages of Meltblown
The advantages of non woven meltblown fabric are following:
- Microfiltration; These meltblown polypropylene fabrics are porous, thus allowing permeation of gases and adding to breathability. Melt blown cloth serves as a good barrier.
- Sorbents; A sorbent is the property of fabric to absorb matter, particularly liquid. So, face masks containing a non woven fabric are the best to prevent oil contamination.
- Increased strength; Meltblown adds greater strength and provides stability to face masks and make them inflexible.
- Temperature resistance; Melt blown helps keep face temperatures down by making the fabric able to neutralize any face heat while being worn.
The melt blown fabric is used in the making of face masks (surgical masks and respirators), thermal insulation materials and oil absorbing materials.
Melt blowing creates ultrafine fibres, making the diameter of fabric up to 1 to 5 microns and supports microfiltration.
The ultra thin fabric increases the surface area of fibres per unit area, making the mask middle layer soft, permeable and breathable.
A Meltblown cloth is the core of any surgical, or respirator face mask; it neutralizes heat and enhances oil absorption.