Development of KF-Rated Face Mask Using Biodegradable and Functional Materials
Abstract
1. Introduction
2. Materials and Methods
2.1. Overview
2.2. Development of Mask Materials
2.3. Function Processing of Nonwovens
2.4. Biodegradability Testing
2.5. KF 94 Rating Test
2.6. Bacterial Filtration Efficiency
2.7. Prototype Development
2.8. Prototype Wearability Evaluation
3. Results
3.1. Nonwoven Production for Biodegradable Material Applications
3.2. Antibacterial Properties and Odor Resistance of Nonwovens
3.3. Functional Evaluation
3.4. Prototype Evaluaion
4. Discussion
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Abbreviations
MB | Melt-blown |
MFDA | Ministry of Food and Drug Safety |
SB | Spunbond |
KF | Korean filter |
PP | Polypropylene |
PLA | Polylactic acid |
PBS | Polybutylene succinate |
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Rating | Criteria | Usage Examples | ||
---|---|---|---|---|
Dust Collection Efficiency | Facial Intake Resistance | Facial Leakage Rate | ||
KF80 | 80.0%+ blockage of average particle size 0.6 μm (Sodium chloride test) | 6.2 mmH2O or less or 60 Pa or less | 25.0% or less | For sulfur |
KF94 | >94% of average particle size of 0.4 μm (Sodium chloride and paraffin oil test) | 7.2 mmH2O or less or 70 Pa or less | 11.0% or less | For sulfur, For quarantine |
KF99 | >99% of average particle size 0.4 μm (Sodium chloride and paraffin oil test) | 10.3 mmH2O or less or 100 Pa or less | 5.0% or less |
Classification | Materials | Manufacturing Method | Weight (g/m2) | |
---|---|---|---|---|
KF 94 | Outer layer | PLA/Cotton | Water punching | 50 |
Interlayer (filter) | PLA MB | Melt blown | 30 | |
Inner layer | Cotton/Tencel | Water punching | 40 |
Physical Properties | |
---|---|
Insularity (dtex) | 1.5 |
Strength (cN/tex) | 32–36 |
Elongation (%) | 50–60 |
Moisture content (%) | 0.4–0.6 |
Number of crimps ea/10 cm | 30–35 |
Sectional shapes | Circle |
Surface Characteristics | Smooth |
Density (g/cm3) | 1.25 |
Melting point (°C) | 170 |
Water weighing | Jade weighing | Binder addition and mixing | Immersion | Drying |
Set natural Content (g) | Sample After Machining | ||
---|---|---|---|
Jade | Water | Binders | |
50 | 180 | 10 |
Metric | |||
1 | Weight | ||
2 | Thickness | ||
3 | Length (folded in half) | Width | |
4 | Height | ||
5 | Ear band (elastic) | Length | |
6 | Width | ||
7 | Between band ends | ||
8 | Position of nose wire | From the top edge | |
9 | Width | ||
10 | Length |
2-Stage Vertical Folding | ||
---|---|---|
1 (Everfresh®) | 2 (Flow®) | 3 (Exploration®) |
4 (Polytechnic®) | 5 (Safe®) | 6 (Line Story®) |
Measurement | ① Weight (g) | ② Thickness (mm) | Length (mm) | |||||||
Type | ③ Width | ④ Height | ||||||||
2-level portrait Folding | 1 | 4.22 | 1.08 | 22.80 | 14.80 | |||||
2 | 4.78 | 0.99 | 23.50 | 15.60 | ||||||
3 | 4.65 | 1.05 | 21.40 | 16.10 | ||||||
4 | 4.49 | 0.98 | 21.60 | 14.30 | ||||||
5 | 5.07 | 1.21 | 18.20 | 14.60 | ||||||
6 | 5.11 | 0.89 | 24.10 | 15.90 | ||||||
Mean | 4.72 | 1.03 | 21.93 | 15.22 | ||||||
S.D | 0.342 | 0.109 | 2.109 | 0.747 | ||||||
Z | −1.746 | −2.529 * | −2.443 * | −3.013 * | ||||||
Measurement | Elastic band (mm) | Position of nose wire (mm) | ||||||||
Type | ⑤ Length | ⑥ Width | ⑦ Between band ends | ⑧ From the top edge | ⑨ Width | ⑩ Height | ||||
2-level portrait Folding | 1 | 16.10 | 0.40 | 4.60 | 0.90 | 9.30 | 0.50 | |||
2 | 15.50 | 0.40 | 5.10 | 1.00 | 10.70 | 0.50 | ||||
3 | 14.80 | 0.30 | 5.50 | 1.00 | 12.10 | 0.40 | ||||
4 | 13.60 | 0.30 | 5.30 | 0.90 | 8.90 | 0.35 | ||||
5 | 16.00 | 0.50 | 5.00 | 0.70 | 11.60 | 0.40 | ||||
6 | 14.50 | 0.30 | 4.80 | 0.80 | 12.30 | 0.40 | ||||
Mean | 15.08 | 0.37 | 5.05 | 0.88 | 10.82 | 0.43 | ||||
S.D | 0.882 | 0.075 | 0.327 | 0.107 | 1.320 | 0.056 | ||||
Z | −1.651 | −1.658 | −2.228 * | −2.443 * | −1.747 | −2.888 * |
Development Design | |
---|---|
Item | Subjects | Average Size for a Woman in Her 30s |
---|---|---|
Mean (S.D.) | Mean (S.D.) | |
Head circumference | 54.5 (1.3) | 55.4 (1.6) |
Head height | 19.1 (1.8) | 22.4 (1.0) |
Head width | 15.3 (0.2) | 16.0 (0.6) |
Nose width | 3.5 (0.1) | 3.1 (0.3) |
Nose height | 1.6 (0.1) | 1.3 (0.2) |
Item | Categorization | Weight (g) | Thickness (mm) | Inhalation Resistance (Pa) | Total Inward Leakage (%) | Size | Layer |
---|---|---|---|---|---|---|---|
M0 | Commercial product | 4.60 | 1.08 | 8.8 | 9 | L | 4 |
M1 | Development (raw) | 4.70 | 1.11 | 6.7 | 9 | L | 3 |
M2 | Development (Jade) | 4.70 | 1.12 | 7.0 | 9 | L | 3 |
NO. | Purpose | Mixing Rate | X150 |
---|---|---|---|
1 | Outer layer | Cotton + PLA (90:10) | |
2 | Cotton + PLA (80:20) | ||
3 | Filter | PLA 100 | |
4 | Inner layer | Cotton + Tencel (90:10) | |
5 | Cotton + Tencel (70:30) | ||
6 | Cotton + Tencel (50:50) |
Category | Conventional KF-Rated Mask (PP/PE-Based) | Developed Biodegradable Mask (PLA/Natural Fiber-Based) | Superior Performance |
---|---|---|---|
Material Type | Polypropylene (PP), Polyethylene (PE) | PLA fiber, Cotton, Tencel (natural fiber blend) | Developed Mask |
Biodegradability | Very low (takes over 450 years to degrade) | Over 70% biodegradation (decomposes within 45 days in compost) | Developed Mask |
Antibacterial Properties | None or only temporary sterilization | Long-lasting antibacterial properties through jade coating (over 99.8%) | Developed Mask |
Odor Resistance | None or limited | Excellent (over 80% deodorization rate) | Developed Mask |
Surface Comfort (Softness) | Slightly rough | Softer touch (cotton + Tencel blending) | Developed Mask |
Environmental Impact | Significant carbon and toxic gas emissions from landfilling or incineration | Reduced carbon emissions and landfill burden via biodegradable materials | Developed Mask |
Filtration Efficiency (KF94) | ≥94% | ≥94% | Equivalent |
Item | M0 | M1 | M2 | X2 | |
---|---|---|---|---|---|
Mean (S.D.) | Mean (S.D.) | Mean (S.D.) | |||
Wear for 15 min | Thermal sensation | 5.0 (1.2) | 4.4 (1.8) | 4.4 (0.8) | 1.462 |
Wetness | 3.0 (1.7) | 4.4 (1.8) | 4.4 (0.7) | 1.152 | |
Comfort | 4.8 (1.0) | 4.6 (1.6) | 4.6 (1.5) | 1.956 | |
Frustration | 4.8 (1.6) | 4.8 (1.7) | 5.0 (1.2) | 2.812 | |
Hygiene | 3.8 (1.1) | 4.0 (1.3) | 4.1 (1.3) | 1.887 | |
Wear for 30 min | Thermal sensation | 5.4 (1.3) | 3.2 (0.9) | 3.4 (1.1) | 5.438 ** |
Wetness | 4.4 (1.6) | 2.2 (1.1) | 2.4 (0.8) | 4.371 * | |
Comfort | 4.8 (1.3) | 5.6 (0.8) | 5.3 (0.6) | 1.294 | |
Frustration | 4.2 (1.2) | 2.8 (0.6) | 2.7 (0.8) | 4.459 * | |
Hygiene | 3.4 (0.8) | 6.1 (0.4) | 6.3 (0.5) | 5.792 ** |
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Kim, H.; Kim, H. Development of KF-Rated Face Mask Using Biodegradable and Functional Materials. Sustainability 2025, 17, 4161. https://doi.org/10.3390/su17094161
Kim H, Kim H. Development of KF-Rated Face Mask Using Biodegradable and Functional Materials. Sustainability. 2025; 17(9):4161. https://doi.org/10.3390/su17094161
Chicago/Turabian StyleKim, Hyunchel, and Hyunah Kim. 2025. "Development of KF-Rated Face Mask Using Biodegradable and Functional Materials" Sustainability 17, no. 9: 4161. https://doi.org/10.3390/su17094161
APA StyleKim, H., & Kim, H. (2025). Development of KF-Rated Face Mask Using Biodegradable and Functional Materials. Sustainability, 17(9), 4161. https://doi.org/10.3390/su17094161