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<p>Medical masks (MMs) engineered to arrest hazardous airborne particles have experienced unprecedented demand following the coronavirus pandemic. To achieve elite protective thresholds against sub-micron bioparticles without inducing physiological breathing resistance, this study systematically integrates sustainable, post-consumer r-PET nanofibers into conventional nonwoven substrates via a three-stage optimization paradigm. In the first stage, functional nanofibers were electrospun onto polypropylene spunbond substrates utilizing r-PET concentrations of 10%, 15%, and 20% w/v across deposition times of 15, 30, and 45&#xa0;min. Comprehensive screening of particulate filtration efficiency (PFE) and aerodynamic pressure drop variations isolated the 10% concentration group as the optimal candidate due to its ultra-fine morphology and balanced permeability. In the second stage, specialized nanofiber networks were engineered onto high-density meltblown substrates using this optimized 10% r-PET solution under identical deposition times to map their localized performance boundaries. In the third stage, specific structural configurations exhibiting the highest Quality Factors (QF) specifically samples C10S30 and C10M15 were combined into distinct multi-layered composite designs. Empirical characterization revealed that the finalized three-layer nanofiber-coated MM configuration achieved an elite sub-micron PFE of 99.1%, while maintaining a static breathing resistance of 270.5&#xa0;Pa, comfortably satisfying the strict requirements specified for European EN 149 (FFP3) and US NIOSH (N99) standards. Capillary flow porometry verified a contracted mean flow pore size of 2.425&#xa0;µm, confirming that these sustainable, mechanically dominant, and charge-decay-immune r-PET nanofiber meshes deliver exceptional biological protection alongside superb physiological breathability.</p>

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Comparison of Recycled Polyethylene Terephthalate (r-PET) Nanofiber Layered Medical Masks with FFP3 (N99) Respirators

  • 期刊论文

  • 发表日期：

    2026年8月5日

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  • Hüsnü Aydemir

摘要

Medical masks (MMs) engineered to arrest hazardous airborne particles have experienced unprecedented demand following the coronavirus pandemic. To achieve elite protective thresholds against sub-micron bioparticles without inducing physiological breathing resistance, this study systematically integrates sustainable, post-consumer r-PET nanofibers into conventional nonwoven substrates via a three-stage optimization paradigm. In the first stage, functional nanofibers were electrospun onto polypropylene spunbond substrates utilizing r-PET concentrations of 10%, 15%, and 20% w/v across deposition times of 15, 30, and 45 min. Comprehensive screening of particulate filtration efficiency (PFE) and aerodynamic pressure drop variations isolated the 10% concentration group as the optimal candidate due to its ultra-fine morphology and balanced permeability. In the second stage, specialized nanofiber networks were engineered onto high-density meltblown substrates using this optimized 10% r-PET solution under identical deposition times to map their localized performance boundaries. In the third stage, specific structural configurations exhibiting the highest Quality Factors (QF) specifically samples C10S30 and C10M15 were combined into distinct multi-layered composite designs. Empirical characterization revealed that the finalized three-layer nanofiber-coated MM configuration achieved an elite sub-micron PFE of 99.1%, while maintaining a static breathing resistance of 270.5 Pa, comfortably satisfying the strict requirements specified for European EN 149 (FFP3) and US NIOSH (N99) standards. Capillary flow porometry verified a contracted mean flow pore size of 2.425 µm, confirming that these sustainable, mechanically dominant, and charge-decay-immune r-PET nanofiber meshes deliver exceptional biological protection alongside superb physiological breathability.