BARRIER FABRIC CONTAINING NANOFIBER LAYER. Marcela MUNZAROVÁ. Nanovia s.r.o., Litvínov, Czech Republic, EU,

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1 , Brno, Czech Republic, EU BARRIER FABRIC CONTAINING NANOFIBER LAYER Marcela MUNZAROVÁ Nanovia s.r.o., Litvínov, Czech Republic, EU, marcela.munzarova@nanovia.cz Abstract The subject of this paper is information on method of production and technical parameters of barrier fabrics containing nanofibers developed and commercialized by Nanovia Ltd. Barrier fabric providing protection against the penetration of microorganisms, dust and pollen particles can be used in the manufacture of face masks. Barrier fabric to prevent the penetration of allergens are applicable in various products of the category of home furnishings. Keywords: nanofibers, nanofiber membranes, nanofiber laminates, barrier fabrics 1. INTRODUCTION Laminated textile fabrics featuring a nanofiber layer bring new functional qualities which conventional textiles (both woven and nonwoven) cannot offer. In those laminates, we use the physical qualities of the nanofiber structure (filtration capability, high porousness, air and steam permeability). By combining the nanofiber structure with woven or nonwoven materials, we achieve the desired parameters, such as strength, wear resistance, feel, look, processability into final products. In this article we can demonstrate the suitability of lamination technologies to produce materials fit for various applications. The examples also demonstrate the option of designing the structure of laminates according to the way of their intended use and, also, they show new ways of applications of nanofiber laminates. Examples of nanofiber structure laminate uses: 1. materials for respiration face masks or disposable filters of PM1, and PM2,5 categories (Nanovia AntiVirus, Nanovia Dust Protection), 2. a barrier preventing the penetration of allergenes and free flying dust during window ventilation (Nanovia Clean Air), 3. barriers preventing the penetration of allergenes (Nanovia AntiAllergy), intended for the manufacture of protective covers and bed linen. 2. LAMINATES FOR FACE MASKS AND DISPOSABLE FILTERS An example of such material is Nanovia AntiVirus SMNF 57 laminated textile fabric intended for the manufacture of filters for face masks. The laminate allows catching viruses, bacteria and fine dust impurities on mechanical principles with more than 99.9 per cent effectiveness. At the same time, the laminate allows processing using cutting and folding technologies. The laminate features a textile base layer (SB/MB composite supplied by Ecotextil s.r.o.), a PVFD polymer nanofiber layer (supplied by Solvay SA), and an upper fabric layer (SB, supplied by PEGAS NONWOVENS a.s.). Using this material and laminating it to the nanofiber layer provides wear or damage protection of the nanofiber both during both the manufacture and use of the filter. The cohesion of all layers is ensured by powder adhesive lamination. The composition of the laminate was designed regarding the requirements of related to the use of the material the manufacture of folded filters; PM 1, category face masks; IIR type surgery masks with enhanced anti-microbial protection, etc.

2 , Brno, Czech Republic, EU Fig. 1 Structure of Nanovia AntiVirus laminat Fig.2 Structure of nanofibrous layer Table 1 Resulting parameters of laminate Nanovia AntiVirus Nanovia AntiVirus SMNF 57 Area weight 57 g/m 2 Strenght 98 N ČSN EN ISO Bacterial filtration Efficiency > 99,9 % ASTM F21 Viral filtration Efficiency > 99,9 % ASTM F21 EN Filtration Efficiency for particles 1, > 99,9 % µm Breathability 44 P (Pa/cm 2 ) ASTM F21 EN Skin irritability - EN ISO Powder adhesive lamination was selected concerning the use of the final material disposable products. The adhesive used for the lamination was an EVA based one (supplied by Dakota company). Another example of a laminate intended for face mask or disposable filters for masks is Nanovia Dust Protection. The laminate is designed as a material for manufacturing filters or PM 2,5 category face masks intended to filter free flying dust. The laminate features a textile base layer (SB, supplied by PEGAS NONWOVENS a.s.), PA6 polymer nanofiber layer (supplied by BASF AG), and an upper fabric layer (SB, supplied by PEGAS NONWOVENS a.s.). Again, the three-layer structure provides for protecting the nanofiber layer against wear or destruction both during the manufacture and use of the filter. Once again, an EVA based powder adhesive (supplied by Dakota company) was used to maintain the layer cohesion. Fig.3 Structure of Nanovia Dust Protection laminate

3 , Brno, Czech Republic, EU Table 2 Resulting parameters of laminate Nanovia Dust Protection Nanovia Dust protection NW 7 Area weight 75 g/m 2 Strength in longitudinal direction 2 N EN ISO Nanofibers diameter 7-1 nm SEM analýza Filtration efficiency for particle size > 99,99 % EN ISO ,5 µm Skin irritability - EN ISO fractional efficiency [%] Fractional fitration efficiency 1,,9,8,7,6,5,4,3,2,1,,,5 1, 1,5 2, 2,5 3, particle size [micron] Antivirus Dust_prot ection_p M_2,5 Sample9 Sample1 Sample11 Sample12 Sample13 Sample14 Sample15 Sample16 Sample17 Sample18 Sample19 Sample2 Fig 4.Comparison of filtration efficiency of both presented materials Nanovia AntiVirus a Nanovia Dust Protection 3. LAMINATE FOR WINDOW VENTILATION The Nanovia Clean Air material was designed for window ventilation application. It is used the same way as insect screens. The nanofiber structure within the laminate allows filtering dust and pollen particles or mold spores. During the design of the material, we considered the fact that the material was going to be exposed to UV radiation, weather, and mechanical stress by wind blows for extensive periods of time. The filtration effectiveness was designed to catch 99.9 percent of 1. µm size particles and thus provide reliable filtering of all allergenes from the ambient environment. The laminate, again, features a textile base layer (UV stabilized SB, supplied by PEGAS NONWOVENS a.s.), PA6 polymer nanofiber layer (supplied by BASF AG), and an upper fabric layer (UV stabilized SB, supplied by PEGAS NONWOVENS a.s.). Again, the three-layer structure provides for protecting the nanofiber layer against wear or destruction both during the manufacture and installation into the window frame. Once again, lamination using an EVA based powder adhesive (supplied by Dakota company) was used to maintain the layer cohesion.

4 , Brno, Czech Republic, EU Fig.5 Structure of Nanovia Clean Air Laminate Table 3 Resulting parameters of Nanovia Clean Air laminate Nanovia Clean Air NW 6 Area weight 65 g/m 2 Strength in longitudinal direction 16 N EN ISO Nanofibers diameter 7-1 nm SEM analýza Filtration efficiency for particle size 1 % EN ISO ,5 µm Filtration efficiency for particle size 99,9 % EN ISO , µm Air Permeability 33 l/m2/s (2 Pa) EN Flammability Non ignition - EN EN LAMINATES DESIGNED AS A BED LINEN MATERIAL FOR PATIENTS SUFFERING FROM ALLERGIES The Nanovia AntiAllergy materials are designed to catch allergenes produced by, dust mites in bed linen. The requirements of the customers (look, feel, wear resistance, washability) brought us to two primary variants of laminates: Nanovia AntiAllergy NW (a combination of nonwoven fabrics), and Nanovia AntiAllergy W (a combination of a non woven fabric and a woven one). The Nanovia AntiAllergy NW variant is a non woven fabric laminate it features base fabric (SB, supplied by PEGAS NONWOVENS a.s.), PA6 polymer nanofiber layer (supplied by BASF), and an upper fabric layer (SB, supplied by PEGAS NONWOVENS a.s.). The Nanovia AntiAllergy NW variant is a laminate consisting of a nonwoven fabric (reverse side) and a woven one (front). The laminate featureseatures base fabric (SB, supplied by PEGAS NONWOVENS a.s.), PA6 polymer nanofiber layer (supplied by BASF), and an upper woven fabric layer (PES fabric, supplied by COMATEX). Considering the requirement of washability, we selected a different lamination technique in this case the hotmelt technology. The technology allows to bond any combination of materials, we can therefore combine a non woven fabric base layer coated with a nanofiber layer with a woven textile fabric of any material composition and weave structure.

5 , Brno, Czech Republic, EU Fig.6 Structure of Nanovia AntiAllergy NW Fig.7 Structure of Nanovia AntiAllergy W Table 4 Resulting parameters of Nanovia AntiAllergy NW 4 Nanovia AntiAllergy NW 4 Area weight 4 g/m 2 Strength in longitudinal direction 1 N ČSN EN ISO Fibers diameter 7-1 nm SEM analýza Filtration efficiency for particle size 99,97 % ČSN EN ISO nm Skin irritability - ČSN EN ISO Flammability Non ignition - EN EN CONCLUSION The use of laminating technologies significantly extends the application scope of nanofiber materials in both traditional industries (filtration) and new industrial segments (interior textiles) of high market potential. By combining suitable materials and using the appropriate lamination technology we can create materials of unique qualities and a high added value for the customer. ACKNOWLEDGEMENT Development of laminated nanofiber membranes was carried out with the support of a grant Ministry of the Interior of the Czech Republic (VG2VS/112) and support of Ministry of Industry and Trade (Nanotex Development Center, program Potential).