Characterization of performance and disinfection resilience of nonwoven filter materials for use in 3D-printed N95 respirators

Validation of N95 respirator models for pressure drop and particle capture efficiency

Despite efforts to apply administrative and engineering controls to minimize worker exposure to aerosols, filtering facepiece respirators (FFRs) continue to be an important form of personal protective equipment in hard-to-control settings such as healthcare, agriculture, and construction. Optimizing the performance of FFRs can be advanced with the use of mathematical models that incorporate the forces that act on particles during filtration as well as those filter characteristics that influence filter pressure drop. However, a thorough investigation of these forces and characteristics using measurements of currently available FFRs has not been undertaken. Filter characteristics such as fiber diameter and filter depth were measured from samples taken from six currently-available N95 FFRs from three manufacturers. A filtration model was developed that included diffusion, inertial and electrostatic forces to estimate the filtration of an aerosol with a Boltzmann charge distribution. The diameter of the filter fibers was modeled as either a single "effective" diameter or as a lognormal distribution of diameters. Both modeling schemes produced an efficiency curve that simulated efficiency measurements made over a range of particle diameters (0.01 - 0.3 µm) with the use of a scanning mobility particle sizer in the region where efficiency is at a minimum. However, the method using a distribution of fiber diameters produced a better fit for particles > 0.1 µm. The coefficients associated with a simple form of the diffusion equation constituting a power law incorporating the Peclet number were adjusted to enhance model accuracy. Likewise, the fiber charge of the electret fibers was also adjusted to maximize model fit but remained within levels reported by others. A filter pressure drop model was also developed. Results demonstrated the need for a pressure drop model applicable to N95s relative to existing models developed with the use of fibers with larger diameters than those used in current N95 FFRs. A set of N95 FFR characteristics are provided that can be used to develop models of typical N95 FFR filter performance and pressure drop in future studies.

Simple fabrication of an electrospun polystyrene microfiber filter that meets N95 filtering facepiece respirator filtration and breathability standards

During the global spread of COVID-19, high demand and limited availability of melt-blown filtration material led to a manufacturing backlog of N95 Filtering Facepiece Respirators (FFRs). This shortfall prompted the search for alternative filter materials that could be quickly mass produced while meeting N95 FFR filtration and breathability performance standards. Here, an unsupported, nonwoven layer of uncharged polystyrene (PS) microfibers was produced via electrospinning that achieves N95 performance standards based on physical parameters (e.g., filter thickness) alone. PS microfibers 3-6 μm in diameter and deposited in an ~5 mm thick filter layer are favorable for use in FFRs, achieving high filtration efficiencies (≥97.5%) and low pressure drops (≤15 mm H₂O). The PS microfiber filter demonstrates durability upon disinfection with hydroxyl radicals (•OH), maintaining high filtration efficiencies and low pressure drops over six rounds of disinfection. Additionally, the PS microfibers exhibit antibacterial activity (1-log removal of E. coli) and can be modified readily through integration of silver nanoparticles (AgNPs) during electrospinning to enhance their activity (≥3-log removal at 25 wt% AgNP integration). Because of their tunable performance, potential reusability with disinfection, and antimicrobial properties, these electrospun PS microfibers may represent a suitable, alternative filter material for use in N95 FFRs.

Efficacy of facemasks in mitigating respiratory exposure to submicron aerosols

We designed a novel experimental set-up to pseudo-simultaneously measure size-segregated filtration efficiency (η_F), breathing resistance (η_P) and potential usage time (t_B) for 11 types of face protective equipment (FPE; four respirators; three medical; and four handmade) in the submicron range. As expected, the highest η_F was exhibited by respirators (97 ± 3%), followed by medical (81 ± 7%) and handmade (47 ± 13%). Similarly, the breathing resistance was highest for respirators, followed by medical and handmade FPE. Combined analysis of efficiency and breathing resistance highlighted trade-offs, i.e. respirators showing the best overall performance across these two indicators, followed by medical and handmade FPE. This hierarchy was also confirmed by quality factor, which is a performance indicator of filters. Detailed assessment of size-segregated aerosols, combined with the scanning electron microscope imaging, revealed material characteristics such as pore density, fiber thickness, filter material and number of layers influence their performance. η_F and η_P showed an inverse exponential decay with time. Using their cross-over point, in combination with acceptable breathability, allowed to estimate t_B as 3.2-9.5 h (respirators), 2.6-7.3 h (medical masks) and 4.0-8.8 h (handmade). While relatively longer t_B of handmade FPE indicate breathing comfort, they are far less efficient in filtering virus-laden submicron aerosols compared with respirators.

Elastomeric Respirators for COVID-19 and the Next Respiratory Virus Pandemic: Essential Design Elements

Respiratory viruses are transmitted via respiratory particles that are emitted when people breath, speak, cough, or sneeze. These particles span the size spectrum from visible droplets to airborne particles of hundreds of nanometers. Barrier face coverings ("cloth masks") and surgical masks are loose-fitting and provide limited protection from airborne particles since air passes around the edges of the mask as well as through the filtering material. Respirators, which fit tightly to the face, provide more effective respiratory protection. Although healthcare workers have relied primarily on disposable filtering facepiece respirators (such as N95) during the COVID-19 pandemic, reusable elastomeric respirators have significant potential advantages for the COVID-19 and future respiratory virus pandemics. However, currently available elastomeric respirators were not designed primarily for healthcare or pandemic use and require further development to improve their suitability for this application. The authors believe that the development, implementation, and stockpiling of improved elastomeric respirators should be an international public health priority.