Rapid sterilizing strategies for N95 respirators to design mission ready PPE for first responders.
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Biological Science↗
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Is atomic layer deposition of silver possible on N95 masks?
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Astaneh, Sarah Hashemi↗
Prototyping of N95 Respirators Using Additive Manufacturing NETL NLVB (Final Report)
Final report for National Energy Technology Laboratory (NETL) project involving the use of advanced manufacturing and 3D printing technologies to help address personal protective equipment (PPE) shortages due to COVID-19. Work was performed in support of Joint DOE Laboratory Plan for Manufacturing Medical Supplies and funded through the DOE Office of Science.
3D Printing↗
Recent developments in filtration media and respirator technology in response to COVID-19
Abstract The COVID-19 pandemic triggered a surge in demand for N95 or equivalent respirators that the global supply chain was unable to satisfy. This shortage in critical equipment has inspired research that addresses the immediate problems and has accelerated the development of the next-generation filtration media and respirators. This article provides a brief review of the most recent work with regard to face respirators and filtration media. We discuss filtration efficiency of the widely utilized cloth masks. Next, the sterilization of and reuse of existing N95 respirators to extend the existing stockpile is discussed. To expand near-term supplies, optimization of current manufacturing methods, such as melt-blown processes and electrospinning, has been explored. Future manufacturing methods have been investigated to address long-term supply shortages. Novel materials with antiviral and sterilizable properties with the ability for multiple reuses have been developed and will contribute to the development of the next generation of longer lasting multi-use N95 respirators. Finally, additively manufactured respirators are reviewed, which enable a rapidly deployable source of reusable respirators that can use any filtration fabric. Graphic abstract
36 MATERIALS SCIENCE↗
Evaluation of an Additively Manufactured Respirator for Personnel Protection from Particulates
Additively manufactured respirators (AMRs) made using rigid plastic can be fitted with repurposed filter media to yield a wearable mask capable of passing a quantitative fit test with criteria set for commercial, N95 health care particulate respirators. This has been verified through an evaluation study assessing AMR masks fabricated using open-source design files and a commercial fused-filament fabrication machine, using N95 filter cloth and a P100 respirator cartridge. A few examples of filter media not designed for human respiratory protection were also evaluated in an AMR mask but did not demonstrate filtering sufficient to pass the N95 test criteria. All attributes of an AMR mask system must be considered during design and when testing performance, including the mask frame, gasket, and the cord used to secure the mask to the face. AMR masks are not the same as commercially available respiratory masks. If AMR masks are used as personal protective equipment (PPE) during a crisis when there is a shortage of regular PPE it is important that wearers are fully informed of the differences, tradeoffs, and risks associated with their use. Quantitative fit testing and proper training on how to don and doff the AMR mask are important to help achieve the best possible outcome when they are used.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Filtration Performance Results: Sierra Peaks Material No. 4
Sandia National Laboratories (SNL) assessed the filtration performance of materials from Sierra Peaks to identify alternatives which may perform similarly to materials used in FDA-approved N95 respirators. This work is meant to characterize the aerosol performance of materials to give Sierra Peaks information for them to determine if they elect to submit masks made using these materials for follow-on N95 certification testing at an accredited facility. The R&D testbed used is a large-scale filtration system designed to test commercial filter boxes. System modifications were performed to simulate, where possible, parameters defined by the National Institute for Occupational Safety and Health (NIOSH) for certification of filter materials for N95 respirators (NIOSH 2019). The system is a pull-through design. Air enters through a Laminar Flow Element (LFE) and the volumetric flow is measured based on the pressure drop across the LFE. Pressure is measured via a Pressure Transducer (PT). The air then passes through a High Efficiency Particulate Air (HEPA) filter to purge the air of ambient airborne particulates. Test aerosol is injected into the flow shortly after and mixing is induced via a coarse mesh. The airflow is allowed to fully develop prior to arriving at the test section. The aerosol then passes through the test material mounted in a box in the test section. Pressure drop across the test article is measured and aerosol sampling probes measure the aerosol concentrations upstream and downstream of the sample. The air passes through a second HEPA filter prior to being exhausted to ambient by a blower. A Topas aerosol generator is used to produce the test aerosol from Sodium Chloride (NaC1) dissolved in deionized (DI) water. Generated aerosol passes through a heated mixing chamber and a desiccant dryer to produce nanosized solid-state particulates. A dilution loop allows for the aerosol concentration to be regulated. The aerosol sampling probes upstream and downstream of the test section are aligned with the flow path. These are ducted directly to the aerosol sizing and counting instruments. A Laser Aerosol Spectrometer (LAS) was used for data collection in the original configuration of the system and was also used for initial testing in this project. Because the lower measurement range for the LAS is 90 nanometers (nm), the LAS was switched out for a more complicated Scanning Mobility Particle Sizer (SMPS) spectrometer system. The SMPS is comprised of an Electrostatic Classifier (EC), Differential Mobility Analyzer (DMA), and a Condensation Particle Counter (CPC). This enabled data collection at 75 nm, the particle size called out in the NIOSH guidelines.
36 MATERIALS SCIENCE↗
Technical Assistance for Characterization Studies of Personal Protection Equipment (PPE) (Final CTAP Report)
Sandia National Laboratories (SNL) conducted an independent assessment of three different certified N95 respirators for the State of New Mexico Department of Homeland Security and Emergency Management. The testing conducted under this effort mimicked traditional NIOSH certification testing methodologies, where possible (NIOSH 2019). This included the use of a commercially available off-the-shelf (COTS) instrument typically used in industry for N95 respirator certification (ATI 2018). The COTS system, an Air Techniques International 100Xs automated filter tester, was used for all the testing reported in this document. It is important to note that SNL is NOT a certification laboratory, and all quantitative results are for informational purposes only. Additional technical information of N95-related efforts conducted by this team may be found in: Omana et al. (2020a), Omana et al. (2020b), Celina et al. (2020)
42 ENGINEERING↗
Inactivation of Human Coronavirus by FATHHOME’s Dry Sanitizer Device: Rapid and Eco-Friendly Ozone-Based Disinfection of SARS-CoV-2
The pandemic of SARS-CoV-2/COVID-19 was reported in December 2019 in Wuhan, China. Pertaining to its high transmissibility and wide host adaptability, this unique human coronavirus spread across the planet inflicting 115 million people and causing 2.5 million deaths (as of March 3rd, 2021). Limited or negligible pre-existing immunity to multiple SARS-CoV-2 variants has resulted in severe morbidity and mortality worldwide, as well as a record-breaking surge in the use of medical-surgical supplies and personal protective equipment. In response to the global need for effective sterilization techniques, this study evaluated the virucidal efficacy of FATHHOME’s self-contained, ozone-based dry-sanitizing device, by dose and time response assessment. We tested inactivation of human coronavirus, HCoV-OC43, a close genetic model of SARS-CoV-2, on porous (N95 filtering facepiece respirator/FFR) and nonporous (glass) surfaces. We started our assays with 20 ppm-10 min ozone exposure, and effectively reduced 99.8% and 99.9% of virus from glass and N95 FFR surfaces, respectively. Importantly, the virus was completely inactivated, below the detection limit (over 6-log10 reduction) with 25 ppm-15 min ozone exposure on both tested surfaces. As expected, a higher ozone exposure (50 ppm-10 min) resulted in faster inactivation of HCoV-OC43 with 100% inactivation from both the surfaces, with no residual ozone present after completion of the 5-min post exposure recapture cycle and no measurable increase in ambient ozone levels. These results confirmed that FATHHOME’s device is suitable for rapid decontamination of SARS-CoV-2- from worn items, frequently touched items, and PPE including N95 FFRs, face shields, and other personal items. View Full-Text
59 BASIC BIOLOGICAL SCIENCES↗
Household Materials Selection for Homemade Cloth Face Coverings and Their Filtration Efficiency Enhancement with Triboelectric Charging
The COVID-19 pandemic is currently causing a severe disruption and shortage in the global supply chain of necessary personal protective equipment (e.g., N95 respirators). The U.S. CDC has recommended use of household cloth by the general public to make cloth face coverings as a method of source control. We evaluated the filtration properties of natural and synthetic materials using a modified procedure for N95 respirator approval. Common fabrics of cotton, polyester, nylon, and silk had filtration efficiency of 5–25%, polypropylene spunbond had filtration efficiency 6–10%, and paper-based products had filtration efficiency of 10–20%. An advantage of polypropylene spunbond is that it can be simply triboelectrically charged to enhance the filtration efficiency (from 6 to >10%) without any increase in pressure (stable overnight and in humid environments). Using the filtration quality factor, fabric microstructure, and charging ability, we are able to provide an assessment of suggested fabric materials for homemade facial coverings.
36 MATERIALS SCIENCE↗
Alumina-based filters made via binder jet 3D printing of alumina powder, colloidal silica infiltration, and sintering
Alumina-based, porous filter media was made via a binder jet 3D printing process consisting of an alumina powder printing step with subsequent heating, colloidal silica infiltration, drying, and sintering to consolidate particles yet retain a net open porous microstructure. The composites made were alumina-silica or alumina-mullite, where the silica sintering aid was used to densify and join the alumina particles. The resulting composite structures had open porosities in the 25–31 vol% range as measured by Archimedes density. Pressure drops were measured across the filter media at constant flow rates to compare disc shapes and complex, 3D printed filters based on the N95 design requirements. Complex, 3D-printed alumina composites were produced with acceptable pressure drops for N95 implementation.
36 MATERIALS SCIENCE↗
Ozone Gas: Scientific Justification and Practical Guidelines for Improvised Disinfection using Consumer-Grade Ozone Generators and Plastic Storage Boxes
Here, we describe direct measurements of ozone concentration achievable in small enclosed containers (plastic storage boxes) for use as improvised decontamination systems for small articles such as disposable PPE (N95 masks, nitrile gloves, etc.), clothing, mail and small packages, food, and other miscellaneous articles. The emphasis is on the reliable and sustained generation of ozone gas concentrations of sufficient concentration and duration to create an effective virucidal environment to achieve more than 95% to 99% viral inactivation, based upon the data already published in the peer-review literature on this topic. The suggestion that ozone be used to inactivate virus is certainly not a new idea. Our objective in this report is to make clear that the necessary levels of ozone can be improvised using simple, easy-to-use, inexpensive, and widely available supplies, and that there is every theoretical and experimental reason to believe that this approach is as highly effective in viral inactivation by ozone as are the far more expensive, complex, cumbersome, and less available equivalent ozone (and other) disinfectant systems that have themselves become unavailable during times of pandemic crisis. Using multiple types of readily available commercial ozone generators, concentration in the tested improvised enclosure is tracked over time to assess ozone charging and decay rates, and the ozone quenching effects of items placed in the box. Generator performance is compared against published ozone dosage values for virucidal and antimicrobial activity. Bubbler and box-fan-type ozone generators were found to be effective at achieving and maintaining target concentrations of 10ppm ozone or higher, whereas automotive cigarette lighter and universal serial bus type plug in “air freshener” ozone generators could not achieve the target concentrations in these experiments. Calculations and practical guidelines for assembly and effective use of an ozone box for improvised decontamination are offered. The majority of this report is directed toward the scientific justification and rationale for this approach. The end of the document summarizes the findings and offers simplified designs for the construction and use of ozone boxes as an improvised method of disinfection.
60 APPLIED LIFE SCIENCES↗
Can disposable masks be worn more than once?
Disposable facemasks are a primary tool to prevent the transmission of SARS-COV-2 during the COVID-19 pandemic. However, plastic waste generated from their disposal represents a significant environmental problem that can be reduced by maximizing the service life of disposable masks. We evaluated the effect of repeated wearing on the fitted filtration efficiency (FFE) of N95, KF94, KN95, and procedure/surgical masks. The FFEs of masks were compared following extended wearing with and without washing. Results reveal that most disposable facemasks can retain a high level of their baseline FFE after extended wearing, even after 40 h of wearing. Laundering disposable masks degraded FFE in some instances. We conclude that the durability of disposable facemask performance is considerably longer than their intended single use indication, suggesting that reusing disposable masks is a safe means of reducing plastic waste in the environment.
54 ENVIRONMENTAL SCIENCES↗
Characterization of Materials Used as Face Coverings for Respiratory Protection
Use of masks is a primary tool to prevent the spread of the novel COVID-19 virus resulting from unintentional close contact with infected individuals. However, detailed characterization of the chemical properties and physical structure of common mask materials is lacking in the current literature. In this study, a series of commercial masks and potential mask materials, including 3M Particulate Respirator 8210 N95, a material provided by Oak Ridge National Laboratory Carbon Fiber Technology Facility (ORNL/CFTF), and a Filti Face Mask Material, were characterized by a suite of techniques, including scanning electron microscopy, X-ray diffraction, Raman spectroscopy, and X-ray photoelectron spectroscopy. Wetting properties of the mask materials were quantified by measurements of contact angle with a saliva substitute. Mask pass-through experiments were performed using a dispersed metal oxide nanoparticle suspension to model the SARS-CoV-2 virus, with quantification via spatially resolved X-ray fluorescence mapping. Notably, all mask materials tested provided a strong barrier against respiratory droplet breakthrough. The comparisons and characterizations provided in this study provide useful information when evaluating mask materials for respiratory protection.
36 MATERIALS SCIENCE↗
Correct Use of Filtering Masks: Five types you'll encounter at LANL
This report provides screenshots of online training on how to use ear loop, tie back, and double elastic face masks made of cloth, surgical, KN95, N95 or homemade materials.
60 APPLIED LIFE SCIENCES↗
Domestic Supply Chain of Medical Consumables Needed During COVID-19 Pandemic
This report is an assessment of the availability, demand, and production capability of medical consumables needed to combat the COVID-19 pandemic. We focus here on the ability of the supply chain to increase production to meet demand during peak pandemic conditions. In addition, we report on domestic production efforts and supply chain issues, as well as the propensity of other countries to limit export of needed medical supplies to the United States. In brief, the domestic supply chain and production capability vary greatly depending on the consumable. Some consumables, such as N95 masks or face shields, can likely be nearly fully supplied by domestic production, while other consumables, such as gloves or surgical masks, have little domestic production and thus will depend on imports to meet demand. The assessment pulls primarily from published news sources and company press releases. As such, the demand and production numbers are not precisely known, and some degree of uncertainty exists in them. The total production capability is also often difficult to ascertain from these reports especially as other industries have begun to supplement existing supply chains. In addition, local conditions (including company financial decisions, local public health issues, and political aspects) can vary throughout the pandemic which will affect future production. The report also pulls from estimates of demand and domestic production of some consumables compiled by the White House COVID-19 Supply Chain Taskforce (SCTF) presented by Rear Admiral John Polowczyk before a June 9, 2020 hearing of the Senate Homeland Security and Governmental Affairs Committee. These numbers, where applicable, are likely to be more accurate than those found in public news sources since they are more directly tied to private companies’ actual orders and actual production estimates, as opposed to publicly released estimates. Finally, we note that other issues with the supply chain, including the production of raw materials, increase demand due to industries that have not previously used PPE now using it, and increased domestic production from non-traditional suppliers, make complete picture of a rapidly changing supply chain difficult to obtain. This report attempts to produce an accurate image of the supply and estimated demand, as understood by the authors who are not experts in the medical supply chain.
42 ENGINEERING↗
A Parameterization Study of Sew-EZ Materials: Types #6 and #8
Two material types identified by Sew-EZ were tested in various configurations, and under various conditions, by Sandia National Laboratories (SNL). The primary focus of this study was to assess the filtration performance of these two materials and identify if they perform similarly to certified N95 respirators. Testing was conducted on two systems which use distinctly different techniques to characterize the aerosol penetration characteristics of materials: a) R&D Filtration System: A large-scale R&D filtration system was used with testing parameters that mimicked NIOSH guidelines, where possible. Efficiency data as a function of particle size was attained using NaC1 as the test aerosol and a Scanning Mobility Particle Sizer (SMPS) for measurements. A more detailed system description can be found in Omana et al. 2020. b) Automated Tester: A commercial, automated filter tester (100Xs, Air Techniques International) was used to provide penetration/efficiency data for Sew EZ materials. The 100Xs aerosolizes a polydisperse NaC1 aerosol with a consistent concentration and size profile. The 100Xs manual (Air Techniques International 2018) states, "The aerosol particle size and distribution are designed to meet all requirements as defined in the relevant sections of NIOSH 42 CFR, Part 84 (pg. 32)."
36 MATERIALS SCIENCE↗
Alternative Materials for Mask Construction by the Public
N95 respirators became scarce to the general public in mid-to-late March of 2020 due to the SARS-CoV-2 epidemic. By mid-April of 2020, most states in the United States were requiring face coverings to be worn while in public enclosed places and in busy outdoor areas where groups of people were in close proximity. Many resorted to cloth masks, homemade masks, procedure masks obtained through online purchases, and other ad-hoc means. Thus, there was and still is a need to determine the aerosol filtration efficacy of commonly available materials that can be used for homemade mask construction. This study focused on non- woven polymeric fabrics that are readily available for homemade mask construction. The conclusion of this study is that non-woven materials that carry a high electric charge or those that can easily acquire charge had the highest aerosol filtration efficiency per unit of pressure drop. Future work should examine a wider variety of these materials and determine the maximum pressure drop that a nominal homemade mask can withstand before a significant portion of airflow is diverted around the mask. More broadly, a better understanding of the charge state on non-woven materials and impact of that charge state on filtration efficiency is needed.
36 MATERIALS SCIENCE↗
Self-Disinfecting Polymeric Coatings
A novel derivative of a previously-published polymeric material has been synthesized and developed into an easily-sprayable coating. Surface characterization of coatings confirm correct elemental presence, and viral assays reveal quantitative elimination of MS2 bacteriophage and Phi6 bacteriophage, surrogates used for SARS-CoV-2, in as little as 5 minutes upon contact. Furthermore, an N95 mask was dip-coated in the polymer solution and analyzed through microscopy and filtration efficacy testing. Though coating was successful, electrostatic interactions between mask layers and polymer reduced filtration efficacy significantly. As such, we expect the current results of this work to be applicable on non-respiratory PPE and on solid substrates of commonly-touched surfaces for rapid self-decontamination.
59 BASIC BIOLOGICAL SCIENCES↗