In non-woven fabric manufacturing, the surgical face masks are produced by \(\underline{\hspace{2cm}}\)
Step 1: Identify the primary need for a surgical face mask: effective filtration of minute particles (bacteria and viruses) coupled with adequate breathability.
Step 2: Analyze the characteristics of webs created by each method.
- Spunbond: Generates webs with good structural integrity, but the comparatively large fiber size results in larger pores and inefficient filtration of very small particles. Used for outer mask layers to provide strength.
- Meltblown: Employs high-speed, hot air to create incredibly fine microfibers from molten polymers. This process yields a web with extremely small pores, making it an exceptional filtration material. This layer is crucial for filtration in surgical masks.
- Carded web: Constructed from staple fibers. While offering some filtration capability, it typically does not achieve the high filtration efficiency required by medical standards, compared to meltblown webs.
- Wet laid: Capable of producing uniform webs, but it is not the standard technology for the high-efficiency filtration media used in masks.
Step 3: Draw a conclusion based on the primary function. Although a complete mask utilizes spunbond for outer layers, the meltblown layer is responsible for the essential filtration. Consequently, among the single technologies mentioned, meltblown is the most critical process for surgical mask production.