METHOD FOR PRODUCING A PERMEABLE MATERIAL THAT FILTERS OUT HARMFUL PARTICLES AND PRODUCTS CREATED THEREFROM

Abstract

A permeable material that allows air to easily pass through the interstices in any direction. The permeable material may be a cloth, a mesh, latex, rubber, or any polymer. The material is saturated with a water and/or alcohol based solution containing either a cationic or anionic agent, a disinfecting agent, and a biocide. The solvent on the permeable material is permitted to evaporate. What remains on the permeable material is the cationic or anionic agent and the biocide. This coated material is now surrounded by an electrostatic field. The electrostatically charged material attracts oppositely charged particles and repels similarly charged particles. The particles that contain living organisms are inactivated by the biocide. The formulations have been shown to have efficacy against rhinovirus causing colds, influenza and corona viruses causing diseases such as swine flu and COVID-19, as well as other harmful airborne microscopic and sub-microscopic particles. The material may be formed into products such as face masks, unitary filters, and filtration devices. Users of these masks might want to periodically spray or otherwise apply the solution to the mask to restore its disinfecting, filtration, and biocidic properties. This would also render normally disposable cloth or surgical face masks reusable.

Claims

1. An electrostatically charged permeable material that filters harmful particulate matter, said material comprising a coating of at least one cationic or anionic agent, at least one disinfecting agent, and at least one biocidic agent, wherein the coating adheres to the material, whereby the electrostatically charged permeable material filters harmful particulate matter by creating a surrounding electrostatic field that: a. repels particulate matter that is similarly charged as the material; b. attracts and holds particulate matter that is oppositely charged as the material; and c. inactivates the harmful effects of the held particulate matter.

2. The material of claim 1 manufactured from cotton, silk, nylon, rayon, polyethylene, polymethyl methacrylate, epoxy, glass, latex, rubber, or any polymer.

3. The material of claim 1 wherein the material has a residual coating of a polyquaternary ammonium compound.

4. The material of claim 1 wherein the material has a residual coating of benzalkonium chloride.

5. The material of claim 1 formed or cut into a desired shape.

6. The material of claim 1 formed into a face mask, thereby inhibiting inhalation of the harmful particulate matter by a person wearing the mask. The material of claim 1 wherein the material is manufactured by coating an existing mask.

8. The material of claim 1 formed into a filter that is inserted into a receptacle of a face mask, thereby inhibiting inhalation of the harmful particulate matter by a person wearing the mask.

9. The material of claim 1 formed into a filter that is inserted into a unit supplying forced air, thereby inhibiting inhalation of harmful particulate matter by those breathing the air.

10. The material of claim 1 formed into a filter that is inserted into a receptacle of a hazmat suit, thereby inhibiting inhalation of the harmful particulate matter by a person wearing the suit.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0011] Given a permeable material of indefinite two-dimensional area and negligible thickness. The material has a front side and a back side. Given its permeability, air can pass through the interstices in either direction. This permeable material, such as a cloth or mesh, is sprayed with a water and/or alcohol based solution containing either a cationic or anionic agent and a biocide. The solution wets both the front side and the back side. The solution is allowed to evaporate. When dry, the material exhibits a charged electrostatic field that extends in all directions away from the front and back sides, and said charge amplitude diminishes as the square of the distance from the material. The electrostatic field will continue for an indefinite duration until something happens to dissipate the charge. Thus, the material may be cut into any shape, and delivered to or shipped to users without losing its charge. Alternatively, the permeable material may be formed into a definite shape during fabrication, thus reducing wasted material due to the cutting process.

[0012] If the solution sprayed onto or otherwise impregnated into the material contains a cationic agent, the material will attract and hold negatively charged particles from the air in the vicinity of the material. It will repel all positively charged particles. On the other hand, if the solution sprayed onto the material contains an anionic agent, material will attract and hold positively charged particles and will repel all negatively charged particles. Most harmful airborne particles possess an electrostatic charge, either positive or negative. Thus, similarly charged harmful particles are repelled and cannot pass through the material. Oppositely charged particles are attracted to the material and held in place by the fibers. The harmful particles may comprise pollen, dust, mold, and pathogens such as bacteria and viruses. The biocide contained in the solution will inactivate virtually all of the pathogens containing living organisms captured by the material, thus rendering them harmless. They may not pass through the material from one side to another in an active state.

[0013] The permeable material that is wetted by coating the solution taught in the Present Invention can be an existing permeable material. Here, the user of the face mask or filtration devices may restore the disinfection, filtration, and bioicidic properties of the mask periodically as intended. Thus, a previously disposable mask may become re-usable by the method taught herein.

[0014] To accomplish the Present Invention, a formulation having at least one polyquaternary ammonium compound is prepared, such compounds, alone or together capable of creating an electrostatic field on and around a surface to which it is applied, including surfaces such as skin, textile (woven and non-woven), and hard surfaces, such as floors, walls, wood, metal, plastic, etc. The formulation is generally aqueous based, but may include non-aqueous solvents used which are compatible with the other formulation components and the application surface to which it is applied. Preferably, the formulation is an aqueous formulation. In addition to the polyquaternary ammonium compound, the composition includes at least one biocide. Furthermore, the composition may contain, but is not required to contain various thickeners, gels, colorants, emollients, humectants, fragrances, and generally other suitable components that are compatible with the end use application and the other components of the formulations.

[0015] Table 3 presents an example of a solution that may be used as a spray in the Present Invention to coat the permeable material.

TABLE-US-00003 TABLE 3 Ingre- Phase/ dient Sequence No. No. Raw Materials Percent PHASE A - Water @ (Ambient Temp.) 1 A1 Distilled Water By Difference 2 A2 Propylene Glycol  5.0 to 15.0% 3 A3 Benzelkonium Chloride 0.05 to 0.25% 50% Solution 4 A4 Polyquaternium-22  2.0 to 12.0% PHASE B - Ethanol @ (Ambient Temp.) 5 B1 Ethanol 40.0 to 70.0% 6 B2 Phenoxyethanol 0.4% to 1.0%.sup.  7 B3 Menthol 0.05% to 0.30%.sup.  8 B4 Fragrance 0.1 to 0.5% Total 100 Incrementally add PHASE A to PHASE B - With continued stirring-mixing for 10-15 minutes

[0016] The solution in this instance contains a cationic agent, thus producing a positive charge. The solution is prepared in two parts—PHASE A (an aqueous solution) and PHASE B (an ethanol solution). PHASE A contains Polyquaternium-22, which is a polyquaternary ammonium compound, that is a cationic agent and a thickener, and benzalkonium chloride which acts as a biocide as well as a cationic agent and thickener. The polypropylene glycol is an excipient and stabilizing agent. PHASE A and PHASE B are prepared separately and then mixed as shown in the table.

[0017] Many of the ingredients utilized in my '802, '497, and '706 Patents as well as those referred to in my '690 Application may also be used in the solutions of the Present Invention.

[0018] Among the Ingredients of the solution there would be: [0019] at least one quaternary thickener, [0020] a preservative, [0021] a conditioner, [0022] a disinfecting agent, [0023] a biocidic agent, [0024] a preservative, and [0025] a thickener,

[0026] It may also contain: [0027] an emollient, [0028] a decongesting agent, [0029] a fragrance, [0030] a humectant, and [0031] a binder.

[0032] Ingredients as shown above and similar materials have been shown to inhibit inhalation of airborne allergens and other harmful particulate matter, and particularly to inhibit inhalation of bacterial and viral pathogens. A permeable material impregnated with a residual coating after evaporation of a wet solution will allow air to pass through purified of these harmful particulates. When held close to the nose or mouth, air passing in either direction will be substantially free of harmful pathogens.

[0033] The impregnated permeable material may be cut into various shapes and patterns. Alternatively a product fabricated from this material can be pre-formed. One use of such a product would be a conventional cloth face mask. Such a mask worn by a healthy person would be protected from inhaling airborne pathogens. In addition, such a mask worn by an infected person would protect others because his exhaled breath, once passing through the cloth, would contain dead pathogens.

[0034] The PHASE B solution shown in Table 3 contains menthol and a fragrance (e.g., sea breeze, mint, etc.). These ingredients make breathing through a mask more acceptable.

[0035] Furthermore, a person wearing such a mask need not worry about the mask fitting tightly around his or her face. Because the mask was cut from a material having a uniform electrostatic charge, air coming onto the user's face from the sides of the mask would also be free of live pathogens.

[0036] Users of these masks might want to periodically spray or otherwise apply the solution to the front side of the mask, which may have become contaminated by contact with infected individuals. This would also render normally disposable cloth or surgical face masks reusable. Furthermore, whenever the mask is washed, the solution would need to be sprayed or reapplied to the mask to recreate the electrostatic field.

[0037] However, the treated permeable material may also be used as a filter in hard masks such as the N95. It would be a particularly appropriate filter material for the ATMOBLUE mask. The ATMOBLUE mask creates a tight, comfortable fit around the nose and mouth using memory foam. The only outside air reaching the nose and mouth enters the region through the two filters, which are replaceable. The only improvement would be that the ATMOBLUE filters would be those of the Present Invention.

[0038] Another embodiment of the Present Invention would be where the permeable material is used to purify the air in a region such as a small room. Here, the permeable material would be placed into air conditioners and changed periodically. Impregnation of the material with the electrostatic coating increases particle filtration efficiency as well as bacterial and viral diminution and disinfection efficacy.

[0039] A further embodiment of the Present Invention would be the use of the permeable material in a hazmat suit or other personal protective equipment to filter out harmful particulate matter and to deactivate bacteria and viruses so as not to be inhaled by a person wearing the suit or equipment.

GLOSSARY

[0040] 1. Permeable Material—a fabricated material having interstices through which gases and some liquids may pass. [0041] 2. Indefinite Two-Dimensional Area—an undefined area that is large enough to provide sufficient material for fabrication. [0042] 3. Face Mask—a device designed to be worn by a person that covers both the nose and mouth of the person.